Lincoln Electric Welder SVM187 A User Manual
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SVM187-A  
October, 2008  
SAE-400 SEVERE DUTY  
For use with machine code numbers 10856, 11199, 11408  
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  
Copyright © Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• 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  
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SAFETY  
ELECTRIC SHOCK can kill.  
ARC RAYS can burn.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
4.a. Use a shield with the proper filter and cover  
plates to protect 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.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
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 nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases.When welding, keep  
• AC Welder with Reduced Voltage Control.  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and below Threshold Limit Values (TLV)  
using local exhaust or mechanical ventilation. In  
confined spaces or in some circumstances, outdoors, a  
respirator may be required. Additional precautions are  
also required when welding on galvanized steel.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5. b. The operation of welding fume control equipment is affected  
by various factors including proper use and positioning of the  
equipment, maintenance of the equipment and the specific  
welding procedure and application involved. Worker expo-  
sure level should be checked upon installation and periodi-  
cally thereafter to be certain it is within applicable OSHA PEL  
and ACGIH TLV limits.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
3.j. Also see Items 6.c. and 8.  
5.d. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
5.e. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
5.f. Also see item 1.b.  
Aug ‘06  
SAE-400 SEVERE DUTY  
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SAFETY  
WELDING and CUTTING  
CYLINDER may explode  
if damaged.  
SPARKS can  
cause fire or explosion.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
the welding sparks from starting a fire.  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
process used and properly operating  
regulators designed for the gas and  
Remember  
that  
welding  
sparks  
and  
hot  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
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.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
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 information for the  
equipment being used.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact can  
cause overheating and create a fire hazard.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate circuits.  
This can create fire hazards or overheat lifting chains or  
cables until they fail.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
6.h. Also see item 1.c.  
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention  
During Welding, Cutting and Other Hot Work”, available from  
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma  
022690-9101.  
6.j. Do not use a welding power source for pipe thawing.  
Jan ‘07  
SAE-400 SEVERE DUTY  
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SAFETY  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
PRÉCAUTIONS DE SÛRETÉ  
prévenir tout risque d’incendie dû aux étincelles.  
Pour votre propre protection lire et observer toutes les instructions  
et les précautions de sûreté specifiques qui parraissent dans ce  
manuel aussi bien que les précautions de sûreté générales suiv-  
antes:  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
8. S’assurer que la masse est connectée le plus prés possible de  
la zone de travail qu’il est pratique de le faire. Si on place la  
masse sur la charpente de la construction ou d’autres endroits  
éloignés de la zone de travail, on augmente le risque de voir  
passer le courant de soudage par les chaines de levage,  
câbles de grue, ou autres circuits. Cela peut provoquer des  
risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
Sûreté Pour Soudage A LʼArc  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher met-  
allique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble de  
soudage et la machine à souder en bon et sûr état defonc-  
tionnement.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à souder  
parce que la tension entre les deux pinces peut être le total  
de la tension à vide des deux machines.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
11. Pour obtenir de plus amples renseignements sur la sûreté, voir  
le code “Code for safety in welding and cutting” CSA Standard  
W 117.2-1974.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie du  
corps.  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:  
a. Utiliser un bon masque avec un verre filtrant approprié ainsi  
qu’un verre blanc afin de se protéger les yeux du rayon-  
nement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
b. Porter des vêtements convenables afin de protéger la peau  
de soudeur et des aides contre le rayonnement de l‘arc.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
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.  
4. Garder tous les couvercles et dispositifs de sûreté à leur place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
Mar ‘93  
SAE-400 SEVERE DUTY  
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SAFETY  
Electromagnetic Compatibility (EMC)  
Conformance  
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May  
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility  
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized  
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.  
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.  
Introduction  
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be  
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions  
are received by other equipment, electrical interference may result. Electrical emissions may affect many  
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled  
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions  
may be required when a welding power source is used in a domestic establishment.  
Installation and Use  
The user is responsible for installing and using the welding equipment according to the manufacturer’s  
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the 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 disturbances must be reduced to the point  
where they are no longer troublesome.  
Note: The welding circuit may or may not be earthed for safety reasons according to national  
codes. Changing the earthing arrangements should only be authorized by a person who is  
competent to access whether the changes will increase the risk of injury, e.g., by allowing  
parallel welding current return paths which may damage the earth circuits of other equip-  
ment.  
Assessment of Area  
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-  
lems in the surrounding area. The following shall be taken into account:  
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the  
welding equipment;  
b) radio and television transmitters and receivers;  
c) computer and other control equipment;  
d) safety critical equipment, e.g., guarding of industrial equipment;  
e) the health of the people around, e.g., the use of pacemakers and hearing aids;  
f) equipment used for calibration or measurement  
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being  
used in the environment is compatible. This may require additional protection measures;  
h) the time of day that welding or other activities are to be carried out.  
L10093  
3-1-96H  
SAE-400 SEVERE DUTY  
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vi  
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SAFETY  
Electromagnetic Compatibility (EMC)  
The size of the surrounding area to be considered will depend on the structure of the building and other  
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.  
Methods of Reducing Emissions  
Mains Supply  
Welding equipment should be connected to the mains supply according to the manufacturer’s recommen-  
dations. If interference occurs, it may be necessary to take additional precautions such as filtering of the  
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding  
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its  
length. The shielding should be connected to the welding power source so that good electrical contact is  
maintained between the conduit and the welding power source enclosure.  
Maintenance of the Welding Equipment  
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.  
All access and service doors and covers should be closed and properly fastened when the welding equip-  
ment is in operation. The welding equipment should not be modified in any way except for those changes  
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and  
stabilizing devices should be adjusted and maintained according 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 the operator could  
receive a shock by touching these metallic components and the electrode at the same time. The operator  
should be insulated from all such bonded metallic components.  
Earthing of the Workpiece  
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size  
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce  
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece  
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con-  
nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some  
countries where direct connection is not permitted, the bonding should be achieved by suitable capaci-  
tance, selected according to national regulations.  
Screening and Shielding  
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate  
problems of interference. Screening of the entire welding installation may be considered for special applica-  
1
tions.  
_________________________  
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)  
product standard for arc welding equipment.”  
L10093  
3-1-96H  
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
vii  
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -  
RETURN TO MAIN INDEX  
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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  
SAE-400 SEVERE DUTY  
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A-1  
A-1  
TABLE OF CONTENTS - INSTALLATION SECTION  
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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  
SAE-400 SEVERE DUTY  
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A-2  
A-2  
INSTALLATION  
TECHNICAL SPECIFICATIONS - SAE-400 SEVERE DUTY  
INPUT - DIESEL ENGINE CODE 10856  
-
Make/Model  
Description  
Speed (RPM)  
Displacement  
Starting  
System  
Capacities  
Perkins  
4 cylinder  
71 HP @  
High Idle 1800  
Low Idle 1100  
Full Load 1725  
256 cu. in  
(4.2 L)  
12VDC batteries  
(2) & Starter  
Fuel: 22.5 gal.  
85.1 L  
1104.42 Diesel  
Engine  
1725 RPM  
Bore x Stroke  
Oil: 8.5 Qts.  
8.04 L  
3.875” x 5.00”  
(98.4 mm x 127.0mm)  
Coolant: 3.6 gal.  
13.63 L  
RATED OUTPUT - WELDER CODES 10856  
(1)  
Duty Cycle  
Welding Output  
Volts at Rated Amps  
60% (NEMA)  
400 amps  
400 amps  
400 amps  
36 volts  
40 volts  
40 volts  
60% (Lincoln Plus)  
100% (Lincoln Plus)  
INPUT - DIESEL ENGINE CODE 11199 &11408  
Make/Model  
Description  
Speed (RPM)  
Displacement  
Starting  
System  
Capacities  
Perkins  
4 cylinder  
68.4 HP @  
1725 RPM  
High Idle 1800  
Low Idle 1100  
Full Load 1725  
269 cu. in  
(4.2 L)  
12VDC batteries  
(2) & Starter  
Fuel: 22.5 gal.  
85.1 L  
1104C-44 Diesel  
Engine  
Bore x Stroke  
Oil: 10.1 Qts.  
9.6 L  
4.13” x 5.00”  
(105 mm x 127mm)  
Coolant: 3.4 gal.  
12.8 L  
RATED OUTPUT - WELDER CODES 11199 &11408  
(1)  
Duty Cycle  
Welding Output  
Volts at Rated Amps  
35% (NEMA)  
500 amps  
400 amps  
400 amps  
40 volts  
100% (Lincoln Plus)  
100% (Lincoln Plus)  
36 volts  
40 volts  
OUTPUT - WELDER AND GENERATOR  
Welding Range  
Open Circuit Voltage  
Auxiliary Power  
80 - 575 Amps  
97 Max. OCV  
@ 1800 RPM  
115/230 VAC  
3000 Watts, 60 Hz.  
100% Duty Cycle  
PHYSICAL DIMENSIONS  
HEIGHT  
WIDTH  
DEPTH  
WEIGHT  
Codes  
50.13 in.  
1273.3 mm  
28.00 in.  
83.00 in.  
2108.2 mm  
11199  
11408  
2,210 lbs.  
1002.4 kg  
711.2 mm  
10856  
2178 lbs.  
988.0 kg  
(1)  
Based on a 10 minute period.  
SAE-400 SEVERE DUTY  
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A-3  
A-3  
INSTALLATION  
Read this entire installation section before you  
CAUTION  
start installation.  
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.  
SAFETY PRECAUTIONS  
WARNING  
Do not attempt to use this equipment until you  
have thoroughly read all operating and mainte-  
nance manuals supplied with your machine. They  
include important safety precautions, detailed  
engine starting, operating and maintenance  
instructions and parts lists.  
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) beyond the equipment on all sides.  
------------------------------------------------------------------------  
STACKING  
These machines cannot be stacked.  
ANGLE OF OPERATION  
ELECTRIC SHOCK can kill.  
To achieve optimum engine performance the machine  
should be run in a level position. The maximum angle  
of operation for the Perkins engine is 30 degrees in all  
directions. If the engine is to be operated at an angle,  
provisions must be made for checking and maintaining  
the oil level at the normal (FULL) oil capacity in the  
engine crankcase. When operating the welder at an  
angle, the effective fuel capacity will be slightly less  
than the specified 22.5 gallons.  
•Do not touch electrically live parts  
such as output terminals or internal  
wiring.  
•Insulate yourself from the work and  
ground.  
•Always wear dry insulating gloves.  
------------------------------------------------------------------------  
LIFTING  
ENGINE EXHAUST can kill.  
The equipment lift bail should be used to lift the  
machine.  
•Use in open, well ventilated areas or  
vent exhaust outside  
•Do not stack anything near the  
engine.  
WARNING  
------------------------------------------------------------------------  
• Lift only with equipment of  
adequate lifting capacity.  
MOVING PARTS can injure.  
• Be sure machine is stable  
•Do not operate with doors open or  
guards off.  
when lifting.  
• Do not lift this machine using  
lift bail if it is equipped with a  
heavy accessory such as trail-  
er or gas cylinder.  
•Stop engine before servicing.  
•Keep away from moving parts  
------------------------------------------------------------------------  
Only qualified personnel should install, use or  
service this equipment  
FALLING  
• Do not lift machine if lift bail is  
damaged.  
EQUIPMENT can • Do not operate machine while  
cause injury.  
suspended from lift bail.  
------------------------------------------------------------------------  
LOCATION/VENTILATION  
The welder should be located to provide an unrestricted  
flow of clean, cool air to the cooling air inlets 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.  
SAE-400 SEVERE DUTY  
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A-4  
A-4  
INSTALLATION  
• 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.  
HIGH ALTITUDE OPERATION  
At higher altitudes, output derating may be necessary.  
As a rule of thumb, derate the welder output 5% for  
every 500 meters (1640 ft.) above 1000 meters (3280  
ft.).  
• Do not exceed maximum rated loads for compo-  
nents such as suspension, axles and tires.  
• Mount equipment base to metal bed or frame of  
vehicle.  
Contact a Perkins Service Representative for any  
engine adjustments that may be required for high alti-  
tude operation.  
• Follow vehicle manufacturerʼs instruction.  
-P--R----E-----O----P--E---R----A---T--I-O----N----E---N----G---I-N---E-----S---E---R---V---I-C---E---  
READ the engine operating and maintenance instruc-  
tions supplied with this machine.  
TOWING  
The recommended trailers for use with this equipment  
for in-plant and yard towing by a vehicle(1) are Lincoln’s  
K767-1 and K956-1. The K956-1 is also designed to be  
ENGINE OIL  
(1)  
The engine is shipped with the engine crankcase filled  
with high quality SAE 10W-30 oil (API class CD or bet-  
ter). Check the oil level before starting the engine. If it is  
not up to the full mark on the dip stick, add oil as required.  
Check the oil level every four hours of running time during  
the first 35 running hours. Refer to the engine Operator’s  
Manual for specific oil recommendations and break-in  
information. The oil change interval is dependent on the  
quality of the oil and the operating environment. Refer to  
the engine Operator’s Manual for the proper service and  
maintenance intervals.  
used at highway speeds .If the user adapts a non-  
Lincoln trailer, he must assume responsibility that the  
method of attachment and usage does not result in a  
safety hazard or damage the welding equipment.  
Some of the factors to be considered are as follows:  
1. Design capacity of trailer vs. weight of Lincoln  
equipment and likely additional attachments.  
2. Proper support of, and attachment to, the base of  
the welding equipment so that there will be no  
undue stress to the trailer’s framework.  
FUEL USE DIESEL FUEL ONLY  
3. Proper placement of the equipment on the trailer to  
insure stability side to side and front to back when  
being moved and when standing by itself.  
WARNING  
• Stop engine while fueling.  
• Do not smoke when fueling.  
• Keep sparks and flame away  
from tank.  
4. Typical conditions of use, such as travel speed,  
roughness of surface on which the trailer will be  
operated, and environmental conditions.  
• Do not leave unattended while  
fueling.  
5. Proper preventative maintenance of trailer.  
• Wipe up spilled fuel and allow  
fumes to clear before starting  
engine.  
DIESEL FUEL  
1
6. Conformance with federal, state and local laws.  
can cause fire.  
(1) For highway use, consult applicable federal, state  
and local laws regarding specific requirements for  
use on public highways, such as brakes, lights, fend-  
ers, etc.  
• Do not overfill tank, fuel  
expansion may cause over-  
flow.  
DIESEL FUEL ONLY  
------------------------------------------------------------------------  
VEHICLE MOUNTING  
Fill the fuel tank with clean, fresh diesel fuel.  
The capacity of the fuel tank is 22.5 gallons (85.1 liters).  
See engine Operator’s Manual for specific fuel recom-  
mendations.  
WARNING  
Improperly mounted concentrated loads may cause  
unstable vehicle handling and tires or other compo-  
nents to fail.  
NOTE: Before attemting to start the engine, be sure the  
fuel shutoff valve is open.  
SAE-400 SEVERE DUTY  
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A-5  
A-5  
INSTALLATION  
BATTERY CONNECTION  
ENGINE BREAK-IN  
WARNING: Use caution as the electrolyte is a strong  
acid that can burn skin and damage eyes.  
Lincoln Electric 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.  
Remove and discard the insulating caps from the neg-  
ative battery terminals. Attach and tighten negative  
battery cable terminals.  
NOTE: This machine is furnished with wet charged  
batteries; if unused for several months, the batteries  
may require a booster charge. Be careful to charge the  
batteries with the correct polarity. Make sure that the  
batteries are level while charging.  
Larger machines with a capacity of 350 amperes and  
higher, which are operated at low or no-load conditions  
for extended periods of time are especially susceptible  
to the conditions described above. To accomplish suc-  
cessful engine break-in, most diesel-powered equip-  
ment needs only to be run at a reasonably heavy load  
within the rating of the welder for some period of time  
during the engine’s early life. However, if the welder is  
subjected to extensive light loading, occasional moder-  
ate to heavy loading of the engine may sometimes be  
necessary. Caution must be observed in correctly  
loading a diesel/generator unit.  
WARNING  
GASES FROM BATTERY can explode.  
● Keep sparks, flame and cigarettes  
away from battery.  
To prevent EXPLOSION when:  
1. Connect the welder output studs to a suit-  
able resistive load bank. Note that any  
attempt to short the output studs by con-  
necting the welding leads together, direct  
shorting of the output studs, or connecting  
the output leads to a length of steel will  
result in catastrophic damage to the gener-  
ator and voids the warranty.  
● INSTALLING A NEW BATTERY — disconnect  
negative cable from old battery first and  
connect to new battery last.  
● CONNECTING A BATTERY CHARGER —  
remove battery from welder by disconnecting  
negative cable first, then positive cable and  
battery clamp. When reinstalling, connect  
negative cable last. Keep well ventilated.  
● USING A BOOSTER — connect positive lead to  
battery first then connect negative lead to neg-  
ative battery lead at the lower control panel  
support.  
2. Set the welder controls for an output cur-  
rent and voltage within the welder rating  
and duty cycle. Note that any attempt to  
exceed the welder rating or duty cycle for  
any period of time will result in catastrophic  
damage to the generator and voids the  
warranty.  
BATTERY ACID can burn eyes and  
skin.  
● Wear gloves and eye protection  
and be careful when working near  
battery.  
3. Periodically shut off the engine and check  
the crankcase oil level.  
● Follow instructions printed on battery.  
ENGINE COOLING SYSTEM  
IMPORTANT: To prevent ELECTRICAL DAMAGE  
WHEN:  
The cooling system has been filled at the factory with  
a 50-50 mixture of ethylene glycol antifreeze and  
water. Check the radiator level and add a 50-50 solu-  
tion as needed. (See Engine Manual or antifreeze  
container for alternate antifreeze recommendation.)  
a) Installing new batteries.  
b) Using a booster.  
Use correct polarity — Negative Ground.  
To prevent BATTERY BUCKLING, tighten nuts on bat-  
teries only until snug. DO NOT OVERTIGHTEN.  
SAE-400 SEVERE DUTY  
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A-6  
A-6  
INSTALLATION  
SPARK ARRESTOR  
MACHINE GROUNDING  
WARNING  
Because this portable engine driven welder creates its  
own power, it is not necessary to connect its frame to  
an earth ground, unless the machine is connected to  
premises wiring (home, shop, etc.).  
WARNING  
• Spark Arrestor and Muffler may be hot!  
Allow engine to cool before servicing spark arrestor!  
Do not operate engine while servicing spark arrestor!  
To prevent dangerous electric shock, other equipment  
powered by this engine driven welder must:  
Some federal, state or local laws may require that  
diesel engines be equipped with exhaust spark  
arrestors when they are operated in certain locations  
where unarrested sparks may present a fire hazard.  
a) be grounded to the frame of the welder using a  
grounded type plug,  
or  
b) be double insulated.  
SAE-400 Severe Duty machines are factory equipped  
with either a muffler that qualifies as a spark arrestor or  
with a separate Spark Arrestor Unit.  
When this welder is mounted on a truck or trailer, its  
frame must be securely connected to the metal frame  
of the vehicle. When this engine driven welder is con-  
nected to premises wiring such as that in a home or  
shop, its frame must be connected to the system earth  
ground. See the article on grounding in the latest U.S.  
National Electrical Code and the local code.  
Qualified mufflers have a clean out service plug, and  
will have “USDA FS 51001C QUALIFIED SPARK  
ARRESTOR” stamped on the muffler shell. If a spark  
arrestor is required, and the muffler is not stamped,  
secure the separate spark arrestor to the outlet tube of  
the muffler using the clamp provided.  
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  
grounding electrical equipment. A machine grounding  
Any type of spark arrestor must be serviced and prop-  
erly maintained.  
CAUTION  
An incorrect spark arrester may lead to damage to  
the engine or adversely affect performance.  
---------------------------------------------------------------------  
stud marked with the  
symbol is provided on the  
welding generator frame foot.  
WELDING OUTPUT CABLES  
With the engine off, connect the electrode and work  
cables to the studs provided. These connections  
should be checked periodically and tightened if neces-  
sary.  
Listed in Table A.1 are copper cable sizes recom-  
mended for the rated current and duty cycle. Lengths  
stipulated are the distance from the welder to work and  
back to the welder again. Cable sizes are increased  
for greater lengths primarily for the purpose of mini-  
mizing cable voltage drop.  
Table A.1 Combined Length of Electrode and  
Work Cables.  
TOTAL COMBINED LENGTH OF ELEC-  
TRODE AND WORK CABLES  
AMPS  
@60%  
Up to 100 FT. 100-200 FT. 200-250 FT.  
(Up to 30m) (30m-61m) (61m-76m)  
Duty Cycle  
400  
2/0 AWG  
3/0 AWG  
4/0 AWG  
SAE-400 SEVERE DUTY  
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B-1  
B-1  
TABLE OF CONTENTS - OPERATION SECTION  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1  
Safety 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  
SAE-400 SEVERE DUTY  
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B-2  
B-2  
OPERATION  
OPERATING INSTRUCTIONS  
WELDING SPARKS can cause  
Read and understand this entire section before operat-  
fire or explosion.  
ing your equipment.  
• Do not weld near flammable material .  
• Do not weld on containers that have  
held flammable material.  
SAFETY INSTRUCTIONS  
Do not attempt to use this equipment until you have  
thoroughly read all operating and maintenance manu-  
als supplied with your machine. They include important  
safety precautions, detailed engine starting, operating  
and maintenance instructions and parts lists.  
---------------------------------------------  
MOVING PARTS can injure.  
• Keep away from moving parts  
• Do not operate with doors open or  
guards off.  
WARNING  
• Stop engine before servicing.  
-------------------------------------------------------  
ENGINE EXHAUST can kill.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrodes with your skin or wet cloth-  
ing.  
• Use in open, well ventilated areas or  
vent exhaust outside.  
------------------------------------------------------------------------  
• Insulate yourself from the work and  
ADDITIONAL SAFETY PRECAUTIONS  
ground.  
• Always wear dry insulating gloves.  
• Do not use AC welder if your clothing, gloves or  
work area is damp or if working on, under or  
inside workpiece.  
Always operate the welder with the hinged doors  
closed as these provide maximum protection from  
moving parts and insure proper cooling air flow.  
Use the following equipment:  
• Semiautomatic DC constant voltage  
(wire) welder.  
Read carefully the Safety Precautions page in the  
Instruction Manual before operating this machine.  
Always follow these and any other safety procedures  
included in this manual and in the engine and com-  
pressor instruction manuals.  
• DC manual (stick) welder.  
• AC welder with reduced voltage con-  
trol.  
------------------------------------------------------------------------  
GENERAL DESCRIPTION  
ARC RAYS can injure eyes and  
burn skin.  
The SAE-400 SEVERE DUTY is a diesel engine driven  
welding power source. The machine uses a DC gener-  
ator for DC stick electrode welding and an AC exciter  
for 115/230 VAC auxiliary power. As a generator it can  
supply up to 3,000 watts of 115/230 volt AC power. As  
a welder it provides up to 575 amps of DC constant  
current output.  
• Wear eye, ear, and body protection.  
----------------------------------------------------------  
• Only qualified personnel should install, use or  
service this equipment.  
• Consult instruction manual before operating.  
----------------------------------------------------------------------  
Before operating, read and understand the manu-  
facturerʼs instructions for this equipment and the  
consumables to be used including the Material  
Safety Data Sheet (MSDS) and follow your  
employerʼs safety practices.  
The engine is a 4-cylinder water cooled diesel made by  
Perkins.  
RECOMMENDED APPLICATIONS  
WELDER  
------------------------------------------------------------------------  
FUMES AND GASES can be  
The SAE-400 SEVERE DUTY provides excellent con-  
stant current DC welding output for stick (SMAW) weld-  
ing.  
dangerous to your health.  
• Keep your head out of fumes.  
• Use enough ventilation or exhaust  
at the arc, or both, to keep the fumes  
and gases from your breathing zone  
and general area.  
AUXILIARY POWER  
The SAE-400 SEVERE DUTY provides 3 KW of  
115/230 VAC output for auxiliary power and emer-  
gency standby power.  
SAE-400 SEVERE DUTY  
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B-3  
B-3  
OPERATION  
DESIGN FEATURES AND ADVANTAGES  
DUTY CYCLE  
FOR STICK WELDING  
Duty cycle is the percentage of time the load is being  
applied in a 10 minute period. For example a 60% duty  
cycle, represents 6 minutes of load and 4 minutes of  
no load in a 10 minute period.  
• Excellent DC constant current output for stick weld-  
ing applications.  
• Continuous adjustment of both voltage and current  
for unsurpassed welds on demanding jobs.  
• Remote control capability standard.  
FOR AUXILIARY POWER  
• 3,000 watts of 115/230 VAC, 60 Hz auxiliary power.  
• One 20 amp 115 VAC duplex receptacle for up to 26  
amps of 115 VAC power.  
• One 15 amp, 230 VAC duplex receptacle for up to 13  
amps of 230 VAC power.  
• Weld and AC auxiliary power at the same time (with-  
in the limits shown on the chart below).  
Welding  
Using Only  
Using Only  
230V Circuit,  
Amps  
Total  
Aux.  
kVA  
Current, Amps 115V Circuit,  
@ NEMA Arc  
Volts  
Amps  
0
26  
19.5  
13  
6.5  
0
13  
9.75  
6.5  
3.25  
0
3.0  
2.25  
1.5  
0.75  
0
100  
200  
300  
400  
500•  
0
0
0
* Codes 11199 and 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 stops. Includes high idle switch.  
• Gauges for engine oil pressure, coolant temperature  
and battery charging ammeter.  
• Engine hour meter standard.  
• Extended range 22.5 gallon (85.1 L) fuel tank.  
SAE-400 SEVERE DUTY  
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B-4  
B-4  
OPERATION  
ENGINE CONTROLS  
IGNITION SWITCH  
ENGINE PROTECTION SYSTEM  
The engine protection system shuts down the engine  
under high coolant temperature, low engine oil pres-  
sure, broken belt or alternator failure conditions by  
allowing the fuel solenoid valve to close.  
When placed in the “ON” position, this switch ener-  
gizes the fuel solenoid. When placed in the “OFF” posi-  
tion, the flow of fuel to the injection pump is stopped to  
shut down the engine.  
AIR INTAKE SHUT-OFF  
“IDLER” SWITCH  
Code 10856:  
The idler switch has two positions, “HIGH” and  
“AUTO”.  
This code uses an air intake shut-off device that is  
manually engaged and blocks all intake air from enter-  
ing the engine.  
When in “HIGH” (  
) position, the engine will run  
continuously at high idle.  
To shut down the engine, simply pull the emergency  
stop handle on the lower control panel.  
When in “AUTO” (  
/ ) idle position, the idler  
operates as follows:  
This air intake shut-off device must be reset manually  
inside of the welder.  
a. Welding  
• Place the Ignition toggle switch in the “off” position.  
When the electrode touches the work, the welding  
arc is initiated and the engine accelerates to full  
speed.  
• Manually turn the air intake shut-off reset handle such  
that the handle is in-line with the air intake hoses. The  
air intake shut-off is located on the top of the engine  
between the muffler and the air filter.  
After welding ceases (and no auxiliary power is  
being drawn), the engine will return to low idle after  
approximately 10 to 14 seconds.  
Codes 11199 and 11408:  
b. Auxiliary Power  
These codes have an automatic/manual device that  
blocks all intake air from entering the engine.  
With the engine running at low idle and auxiliary  
power for lights or tools is drawn (approximately  
100-150 watts or greater) from the receptacles, the  
engine will accelerate to high speed. If no power is  
being drawn from the receptacles ( and not weld-  
ing) for 10-14 seconds, the idler reduces the engine  
speed to low idle.  
The automatic feature of this shut-off device will  
engage should excessive over speeding occur. The  
valve is calibrated at the factory to shutdown before  
damage occurs to the engine or generator.  
To manually shut down the engine, simply pull the  
emergency stop handle on the lower control panel.  
ENGINE TEMPERATURE GAUGE  
This air intake shut-off device will reset automatically,  
generally within one minute.  
Displays the coolant temperature in the engine block.  
ENGINE OIL PRESSURE GAUGE  
IMPORTANT: Before restarting engine, verify that the  
air intake shut-off is in the open position. DO NOT  
ATTEMPT TO START ENGINE WITH THE AIR  
INTAKE SHUT-OFF IN THE CLOSED POSITION.  
Displays the oil pressure to the engine. When the  
engine starts running, watch for the oil pressure to  
build up. If no pressure shows within 30 seconds, stop  
the engine and consult the engine instruction manual.  
WARNING  
BATTERY CHARGING AMMETER  
Displays the current going from the charging alternator  
into the batteries. It is normal for charging current to be  
high (above 15 amps) after starting or when the batter-  
ies are ‘low’ on charge.  
•
Muffler and Engine may be hot!  
ENGINE HOUR METER  
This may cause severe damage to the engine.  
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.  
SAE-400 SEVERE DUTY  
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B-5  
B-5  
OPERATION  
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.  
WELDER CONTROLS  
POLARITY SWITCH  
Turn the Arc Polarity switch to electrode positive or  
electrode negative as required for each particular  
application.  
5. If dialing the desired current with the “Job  
Selector” moves the setting outside the black  
range causing undesirable arc characteristics, turn  
the “Job Selector” back to the center of the black  
range. Then turn the “Current Control” up or down  
a little as needed. Readjust the “Job Selector” for  
the exact characteristics and current desired.  
CONTROL OF WELDING CURRENT  
Purpose of Controls  
The continuous “Current Control” is the main current  
adjuster. The “Job Selector” is both a fine current  
adjuster and the continuous Open Circuit Voltage  
adjuster. Open Circuit Voltage (OCV) controls the arc  
characteristics.  
REMOTE CONTROL  
“Job Selector”  
A receptacle and “Local/Remote” control switch on the  
lower front control panel and a remote control box with  
100 ft. (30.5 m) of cord for adjusting the OCV at the  
welding site are standard. Putting the switch in the  
“REMOTE” position allows fine current control at the  
remote control box while placing the switch in the  
“LOCAL” position allows fine current control at the “Job  
Selector” on the machine.  
The “Job Selector” dial is divided into four colored sec-  
tions providing OCV ranges as follows:  
Color  
Title  
OCV Range  
High OCV  
White  
Large Electrodes  
Normal Welding  
Black  
Red  
Medium OCV  
Overhead & Vertical Low OCV  
Grey  
Special Applications Extra-Low OCV  
AUXILIARY POWER CONTROLS  
The “Job Selector” is usually set in the black range  
because it provides a soft “Buttering “ arc desired for  
most welding. Some operators prefer to set the “Job  
Selector” in the red range for a snappy “Digging” arc  
when welding vertical up or overhead.  
Note: GFCI receptacles are an option and if installed,  
see the “MAINTENANCE SECTION” for detailed  
information on testing and resetting the GFCI  
receptacle.  
“Current Control”  
115 VAC Receptacle  
CAUTION  
One 20 amp, 115 VAC duplex receptacle provides 115  
VAC for auxiliary power. A total of 26 amps can be  
drawn from this receptacle.  
Do not adjust the “Current Control” while welding  
because this can damage the control.  
------------------------------------------------------------------------  
The “Current Control” dial is calibrated in amperes on  
three separate colored dials corresponding to the  
white, black and red ranges of the “Job Selector” dial.  
For example: when the “Job Selector” is set on the  
black range, the approximate welding current is indi-  
cated on the black scale of the “Current Control” dial.  
230 VAC Receptacle  
One 15 amp, 230 VAC duplex receptacle provides 230  
VAC for auxiliary power. A total of 13 amps can be  
drawn from this receptacle.  
Circuit Breakers  
How to Set the Controls  
The circuit breakers provide separate overload current  
protection for each half of the 115 V duplex receptacle.  
The circuit breakers provide overload current protec-  
tion in both current carrying wires of the 230 V duplex  
receptacle.  
Assume you want a normal soft arc and about 135  
amps, using a 5/32” (4.0 mm) electrode:  
1. Set the “Job Selector” at the center of the black  
range.  
Ground Stud  
2. Set the “Current Control” to read 135 amps on the  
black dial.  
Provides a connection point for connecting the  
machine to earth ground. For the safest grounding pro-  
cedure refer to “Machine Grounding” in the INSTAL-  
LATION section of this manual.  
3. Start to weld.  
SAE-400 SEVERE DUTY  
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B-6  
B-6  
OPERATION  
5. Observe the oil pressure. If no pressure shows  
within 30 seconds, stop the engine and consult the  
engine operating manual. To stop the engine, turn  
the “IGNITION” switch to “OFF”.  
ENGINE OPERATION  
WARNING  
Do not attempt to use this equipment until you  
have thoroughly read the engine manufacturerʼs  
manual supplied with your welder. It includes  
important safety precautions, detailed engine  
starting, operating and maintenance instructions,  
and parts lists.  
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 for the oil to drain into the pan. If the level is  
down, fill it to the full mark again. The engine con-  
trols were properly set at the factory and should  
require no adjusting when received.  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
ENGINE EXHAUST can kill.  
COLD WEATHER STARTING  
• Use in open, well ventilated areas or  
vent exhaust outside.  
WARNING  
Under NO conditions should ether or other starting  
fluids be used!  
------------------------------------------------------------------------  
MOVING PARTS can injure.  
------------------------------------------------------------------------  
Code 10856  
• Do not operate with doors open or  
guards off.  
o
o
When overnight temperatures are between 10 F(12 C)  
and freezing, use the standard “Thermostart” starting  
system installed on all engines. Follow the instructions  
on the start panel nameplate and in the engine manu-  
al shipped with the welder. With fully charged batteries  
and the proper weight oil, the “Themostart” system  
• Stop engine before servicing.  
• Keep away from moving parts.  
------------------------------------------------------------------------  
See additional warning information at the  
front of this operatorʼs manual.  
o
operates satisfactorially even down to about 0 F(-  
o
18 C).  
For added safety always operate the welder with the  
doors closed. Further, leaving the doors open changes  
the designed air flow and may cause engine, genera-  
tor overheating.  
Codes 11199 and 11408  
With a fully charged battery and the proper weight oil,  
the engine should start satisfactorily even down to  
about -5°F (-20°C). It maybe desirable to install cold-  
starting aides at lower temperatures.  
CAUTION  
Do not adjust the high idle engine speed (rpm)  
above the factory setting specification as this will  
void warranty.  
Note: Extreme cold weather staring may require longer  
glow plug operation.  
------------------------------------------------------------------------  
STARTING INSTRUCTIONS  
Be sure all Pre-Operation Maintenance has been  
performed. (See INSTALLATION section of this  
manual).  
STOPPING THE ENGINE  
1. Turn the “IGNITION” switch to “OFF”  
At the end of each day’s welding, check the crankcase  
oil level, drain accumulated dirt and water from the  
water separator and refill the fuel tank to minimize  
moisture condensation in the tank. Also, running out of  
fuel tends to draw dirt into the fuel system.  
1. Turn the “IDLER” switch to “HIGH”.  
2. Turn the “IGNITION” switch to “ON”.  
3. Press the Glow Plug button for 20 to 30 seconds.  
(maximum 60 seconds). (codes 11199 and 11408  
only).  
When hauling the welder between job sites, close the  
fuel shut-off valve.  
4. Press the Glow Plug and the Start buttons at the  
same time. When the engine starts running,  
release buttons. If the engine fails to start in 20  
seconds, wait 30 seconds and repeat the above  
procedure. Press the Start button only for code  
10856.  
If the fuel supply is cut off or runs out while the fuel  
pump is operating, air may be entrapped in the fuel dis-  
tribution system. If this happens, bleeding of the fuel  
system may be necessary. Use qualified personnel to  
do this per the instructions in the MAINTENANCE sec-  
tion of this manual.  
SAE-400 SEVERE DUTY  
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B-7  
B-7  
OPERATION  
TYPICAL FUEL CONSUMPTION  
The typical fuel consumption of the SAE-400 for various operat-  
ing scenarios is shown below:  
11199 + 11408  
.30 gal./ hr.  
10856  
Low Idle - No Load  
1100 RPM  
.35 gal./hr  
(1.32 L/hr)  
(1.12 L./hr.)  
High Idle - No Load  
1800 RPM  
.69 gal./hr.  
(2.61 L./hr.)  
.75 gal./hr  
(2.84 L/hr)  
Welding Load  
1.79 gal./hr.  
(6.76 L./hr.)  
1.92 gal./hr  
(7.27 L/hr)  
400 Amps, 40 Volts  
Welding Load  
2.43 gal./hr.  
(9.19 L./hr.)  
500 Amps, 40 Volts  
Auxiliary Power  
3000VA  
.71 gal./hr.  
(3.68 L./hr.)  
.96 gal./hr  
(3.63 L/hr)  
SAE-400 SEVERE DUTY  
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B-8  
B-8  
NOTES  
SAE-400 SEVERE DUTY  
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C-1  
C-1  
TABLE OF CONTENTS - ACCESSORIES SECTION  
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1  
Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2  
SAE-400 SEVERE DUTY  
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C-2  
C-2  
ACCESSORIES  
OPTIONAL FIELD INSTALLED  
ACCESSORIES  
K802-D Power Plug Kit - Kit includes male plugs for  
20 Amp receptacle.  
K2641-1 Trailer - A 4-wheel steerable trailer for in-  
(1)  
plant and yard towing with E78-14 load range (B)  
tubeless tires. Mounts directly to welder base.(Not for  
use on the highway.) Comes standard with a Duo-Hitch™, a  
2” Ball and Lunette Eye combination Hitch.  
(1)  
K2637-1 Trailer - A 2-wheel trailer designed for road ,  
off road, in-plant and yard towing. Trailer mounts  
directly 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  
1
For 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, headshield, work clamp and elec-  
trode holder.  
K1690-1 GFCI RECEPTACLE KIT  
Includes one UL approved 120V ground fault circuit  
interrupter duplex type receptacle with cover and  
installation instructions. Replaces the factory installed  
120V duplex receptacle. Each receptacle of the GFCI  
Duplex is rated at 20 Amps, the maximum total current  
from the GFCI Duplex is limited to the 20 Amps. See  
the MAINTENANCE section for detailed information on  
testing and resetting the GFCI receptacle.  
SAE-400 SEVERE DUTY  
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D-1  
D-1  
TABLE OF CONTENTS - MAINTENANCE SECTION  
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  
SAE-400 SEVERE DUTY  
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D-2  
D-2  
MAINTENANCE  
WARNING  
4. Belts tend to loosen after the first 30 or 40 hours of oper-  
ation. Check the cooling fan belt and tighten if necessary.  
DO NOT OVER TIGHTEN.  
ELECTRIC SHOCK can kill.  
●
Do not touch electrically live parts  
ENGINE OIL CHANGE  
such as output terminals or inter-  
nal wiring  
The SAE-400 SEVERE DUTY is equipped with a convenient  
oil drain system. Drain the oil when the engine is warm to  
assure rapid and complete draining.  
ENGINE EXHAUST can kill.  
● Use in open, well ventilated areas  
• Remove the oil filler cap and dipstick.  
or vent exhaust outside  
• To open drain valve, push handle away from valve and turn  
90°.  
MOVING PARTS can injure.  
● Do not operate with doors open or  
• Drain oil into a suitable container.  
guards off  
Stop engine before servicing  
• To close drain valve, turn handle 90° till handle snaps in the  
closed position.  
●
● Keep away from moving parts  
• Refill engine with the recommended oil to the appropriate  
● Remove guards only when necessary and  
replace when work requiring removal is com-  
plete.  
level. Replace dipstick and tighten the oil filler cap secure-  
ly.  
●
Only qualified personnel should install, use, or  
Change the crankcase oil at regular intervals using the prop-  
er grade of oil as recommended in the Engine Operating  
Manual. Wash your hands with soap and water after handling  
used oil. Please dispose of used motor oil in a manner that is  
compatible with the environment. We suggest you take it in a  
sealed container to your local service station or recycling  
center for reclamation. Do not throw it in the trash, pour it on  
the ground or down a drain.  
service this equipment.  
ROUTINE MAINTENANCE  
At the end of each day’s welding, refill the fuel tank to  
minimize moisture condensation in the tank. Also, run-  
ning out of fuel tends to draw dirt into the fuel system.  
Check the engine crankcase oil level.  
ENGINE AIR FILTER  
If the fuel supply runs out while the fuel pump is oper-  
ating, air may be entrapped in the fuel distribution sys-  
tem. If this happens, bleeding of the fuel system may  
be necessary. See the engine instruction manual.  
The engine air filter element is a dry cartridge type. It  
is located above the engine. It can be cleaned and re-  
used; however, damaged elements should not be  
washed or re-used. Remove loose dirt from element  
with compressed air or water hose directed from inside  
out. Compressed Air: 100 psi maximum. The filter  
should never be removed while the engine is running.  
PERIODIC MAINTENANCE  
1. Blow out the welder and controls with an air hose at least  
once every two months. In particularly dirty locations, this  
cleaning may be necessary once a week. Use low pres-  
sure air to avoid driving dirt into the insulation.  
2. The current control reactor brushes are self-lubricating  
and should not be greased. Keep the contacts clean. This  
control should be moved from maximum to minimum daily  
to prevent the controls from sticking.  
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.  
SAE-400 SEVERE DUTY  
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D-3  
D-3  
MAINTENANCE  
BEARING MAINTENANCE  
To seat the slip ring brushes, position the brushes in  
place. Then slide one end of a piece of fine sandpaper  
between slip rings and brushes with the coarse side  
against the brushes. Pull the sandpaper around the cir-  
cumference of the rings, in direction of rotation only -  
until brushes seat properly. In addition, stone slip ring  
with a fine stone. Brushes must be seated 100%.  
This welder is equipped with a double-shielded ball bearing  
having sufficient grease to last indefinitely under normal ser-  
vice. Where the welder is used constantly or in excessively  
dirty locations, it may be necessary to add one-half ounce of  
grease per year. A pad of grease one inch wide, one inch  
long and one inch high weighs approximately one-half  
ounce. Over greasing is far worse than insufficient greasing.  
Arcing or excessive exciter brush wear indicates a pos-  
sible misaligned shaft. Have an authorized Field  
Service Shop check and realign the shaft.  
When greasing the bearings, keep all dirt out of the area.  
Wipe the fittings completely clean and use clean equipment.  
More bearing failures are caused by dirt introduced during  
greasing than from insufficient grease.  
COOLING SYSTEM  
COMMUTATOR AND BRUSH MAINTENANCE  
The SAE-400 SEVERE DUTY is equipped with a pres-  
sure radiator. Keep the radiator cap tight to prevent  
loss of coolant. Clean and flush the cooling system  
periodically to prevent clogging the passage and over-  
heating the engine. When antifreeze is needed, always  
use the permanent type.  
WARNING  
Uncovered rotating equipment can be dangerous.  
Use care so your hands, hair, clothing or tools do  
not catch in the rotating parts. Protect yourself  
from particles that may be thrown out by the rotat-  
ing armature when stoning the commutator.  
------------------------------------------------------------------------  
The generator brushes are properly adjusted when the  
welder is shipped. They require no particular attention.  
DO NOT SHIFT THE BRUSHES or adjust the rocker  
setting.  
FUEL FILTERS  
WARNING  
When working on the fuel system  
• Keep ungrounded lights away, do not  
smoke !  
Shifting of the brushes may result in:  
- Change in machine output  
- Commutator Damage  
• Do not spill fuel !  
- Excessive brush wear  
------------------------------------------------------------------------  
The SAE-400 SEVERE DUTY is equipped with a Fuel  
Pre-Filter/Water Separator Assembly located before  
the lift pump and a Secondary Fuel Filter located after  
the lift pump and before the fuel injectors. The Fuel  
Pre-Filter/Water Separator is mounted to the engine  
block just below the lift pump.  
Periodically inspect the commutator, slip rings and  
brushes by removing the covers. DO NOT remove or  
replace these covers while the machine is running.  
Commutators and slip rings require little attention.  
However, if they are black or appear uneven, have  
them cleaned by an experienced maintenance person  
using fine sandpaper or a commutator stone. Never  
use emery cloth or paper for this purpose.  
The Secondary Fuel Filter is mounted directly to the  
engine just above the oil filter.  
FUEL PRE-FILTER/WATER SEPARATOR ASSEMBLY  
NOTE: If the welder is used in dirty or dusty locations,  
or if the welder is not used for prolonged peri-  
ods of time, it may be necessary to clean the  
commutator and slip rings more often.  
The pre-filter is a 150 micron screen designed to pro-  
tect against gross fuel contamination of the water sep-  
arator element and the Secondary Fuel Filter. If the  
pre-filter becomes plugged it may be removed, inspect-  
ed, cleaned and reinstalled. In general this only needs  
to be done with each water separator element change  
(about every 1,000 hrs.) However if at any time exces-  
sive fuel contamination is suspected or a sudden fall-  
off in engine performance is detected the pre-filter  
screen should be inspected and cleaned. Follow the  
following procedure:  
Replace brushes when they wear within 1/4" of the pig-  
tail. A complete set 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.  
SAE-400 SEVERE DUTY  
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D-4  
D-4  
MAINTENANCE  
1. Close the fuel shutoff valve located under the fuel  
tank. (on code 10856 valve is located on the fuel  
strainer, which is mounted on tank)  
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 into the filter header. Now rotate the  
element (may take almost 1 full turn) with a slight  
upward pressure until the element begins to further  
engage the header. With the proper orientation now  
established apply additional pressure to seat the ele-  
ment in the filter header. You should feel the element  
“pop” into place when properly seated.  
2. Unscrew the cap ring located on the top of the filter  
header and remove the plastic center cap and O-  
ring.  
3. Remove the large white volume plug located direct-  
ly under the center cap in the upper cavity of the fil-  
ter header. Use a small screwdriver (or similar  
device) to lift the plug part way out of the cavity to  
assist with its removal.  
Note: The element will only go on one way. Never use  
excessive force when mounting the element to the  
header.  
Be careful not to damage the pre-filter screen with the  
tool used to remove the plug.  
5. Slide the quick change ring up over the element and  
rotate counter clockwise until an audible click or pop  
is heard. If you do not hear the click you have not rotat-  
ed the ring far enough and the element is not in the  
locked position. Another indication that the ring is in  
the locked position is that one set (it doesn’t matter  
which one) of arrows located on the outside of the ring  
should be located directly under the air vent valve.  
4. Using a pair of pliers, gently tug on the pull tabs of  
the pre-filter screen in an alternating pattern to  
gradually remove the pre-filter screen.  
5. Brush off any debris and rinse in diesel fuel.  
6. Re-install the pre-filter screen into the upper cavity  
of the filter header making sure the four pull tabs  
are pointing up. Putting your fingers on the pull  
tabs, push down evenly until the lower body of the  
pre-filter screen contacts the floor of the upper cav-  
ity.  
6. Open the fuel shutoff valve.  
7. Open the air vent valve on the front of the filter head-  
er until fuel emerges free of air bubbles and then close  
the air vent valve.  
7. Re-insert the large white volume plug into the upper  
cavity.  
Note : Consult your engine operation manual for informa-  
tion on air bleeding the entire fuel system.  
8. Place the O-ring onto the angled seal surface of the  
filter header and re-install the plastic cap. Make  
sure its flange rests on the O-ring.  
SECONDARY FUEL FILTER  
The Secondary Fuel Filter has a quick change element  
mounted to the engine similar to the Water Separator.  
Consult your engine operation manual for complete infor-  
mation on service intervals and element changing proce-  
dures.  
9. Screw on the cap ring and tighten hand tight.  
10. Remember to open the fuel shutoff valve before  
starting the engine.  
ENGINE MAINTENANCE COMPONENTS  
WATER SEPARATOR ELEMENT  
ITEM  
Engine Air Filter  
Fan Belt  
MAKE  
Donaldson  
Perkins  
PART NUMBER  
PART NUMBER  
P181052  
11199 & 11408 10856  
P822768  
The water separator element is a two stage filter with a  
special filtration/water separating media, and an  
expanded water reservoir providing maximum protec-  
tion against water in the fuel. The recommended  
change interval for the water separator element is  
1,000 hours. The procedure for changing the element  
is as follows:  
26148555043  
2614B550  
Water Seperator  
Element  
Lincoln  
Stanadyne  
M16890-C  
31572  
M16890-C  
31572  
Fuel Pre-Filter Screen  
Fuel Filter  
Lincoln  
Stanadyne  
M16890-B  
29575  
M16890- B  
29575  
Perkins  
Perkins  
26560201  
2654407  
26560143  
2654403  
1. Close the fuel shutoff valve located under the fuel  
tank.  
Engin Oil Filter  
2. Rotate the quick change ring (located just below fil-  
ter header) clockwise approximately 1/2 turn and  
slide it down and off of the element.  
SAE-400 SEVERE DUTY  
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D-5  
D-5  
MAINTENANCE  
GFCI RECEPTACLE TESTING AND RESET-  
TING PROCEDURE  
SPARK ARRESTOR  
WARNING  
The GFCI receptacle should be properly tested at least  
once every month or whenever it is tripped. To proper-  
ly test and reset the GFCI receptacle:  
WARNING  
•
Spark Arrestor and Muffler may be hot!  
Allow engine to cool before servicing spark arrestor!  
• If the receptacle has tripped, first carefully remove  
any load and check it for damage.  
Do not operate engine while servicing spark arrestor!  
• If the equipment has been shut down, it must be  
restarted.  
For machines with separate spark arresting unit:  
• The equipment needs to be operating at high idle  
speed and any necessary adjustments made on the  
control panel so that the equipment is providing at  
least 80 volts to the receptacle input terminals.  
• The circuit breaker for this receptacle must not be  
tripped. Reset if necessary.  
Service the spark arrestor every 100 hours of opera-  
tion or twice a year, which ever occurs first.  
Service as follows:  
1. Stop engine and allow to cool.  
• Push the "Reset" button located on the GFCI recep-  
tacle. This will assure normal GFCI operation.  
• Plug a night-light (with an "ON/OFF" switch) or other  
product (such as a lamp) into the GFCI receptacle  
and turn the product "ON".  
2. Loosen clamp and remove spark arrestor from  
machine.  
3. Remove locknut on top of spark arrestor housing  
and lift off cap.  
• Push the "Test" button located on the GFCI recepta-  
cle. The night-light or other product should go "OFF".  
• Push the "Reset" button, again. The light or other  
product should go "ON" again.  
4. Seperate plates and clean if necessary.  
5. Inspect plates and housing for holes or cracks.  
Replace spark arrestor if damaged.  
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.  
6. Assemble spark arrestor using reverse order:  
step 3, then step 2.  
For machines with integral spark arresting muf-  
flers:  
Service spark arrestor every 250 hours.  
Service as follows:  
1. Stop engine and allow to cool.  
2. Remove clean out plug from the side of the spark  
arrestor.  
3. Without damaging the spark arrestor, gently tap on  
the shell near the clean out plug.  
4. Once particles are removed, replace the clean out  
plug.  
SAE-400 SEVERE DUTY  
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D-6  
D-6  
NOTES  
SAE-400 SEVERE DUTY  
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E-1  
E-1  
TABLE OF CONTENTS-THEORY OF OPERATION SECTION  
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1  
Engine Starting and Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2  
Automatic Engine Idle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3  
Exciter/Auxiliary Alternator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4  
Welding Generator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6  
FIGURE E.1 BLOCK LOGIC DIAGRAM  
ELECTRODE  
TERMINAL  
OUTPUT  
CONTROL  
MIN  
MAX  
(OFF)  
AC  
AC  
(-)  
(+)  
REMOTE  
RHEOSTAT  
LOCAL  
RHEOSTAT  
POLARITY  
SWITCH  
(JOB SELECTOR)  
THERMOSTART  
BUTTON  
TO HOUR METER  
FLASHING  
RESISTOR  
RESISTOR AND  
DIODE  
(+)  
(-)  
SHUNT COILS  
SERIES COILS  
THERMOSTAT  
TO IDLE / ENGINE  
PROTECTION BOARD  
INJECTION  
PUMP  
EXCITER  
WINDING  
SOLENOID  
SYSTEM  
(-)  
(+)  
TO IDLE/ENGINE  
GENERATOR  
ARMATURE  
EXCITER  
ROTOR  
PROT. BOARD  
DIESEL  
ENGINE  
AUXILIARY  
POWER  
S
T
A
R
T
E
R
WINDINGS  
INTERPOLE COILS  
STARTER  
OIL  
SOLENOID  
PRESSURE  
SWITCH  
TEMP  
SWITCH  
IDLE  
IDLE SWITCH  
RUN/STOP  
SWITCH  
SOLENOID  
115 VAC  
RECEPTACLES  
230 VAC  
RECEPTACLES  
IDLE / ENGINE  
HOUR  
METER  
PROTECTION BOARD  
AMMETER  
WORK  
TO  
TERMINAL  
FLASHING  
RESISTOR  
AND  
ENGINE  
TO ALTERNATOR  
FLASH/SENSE  
START  
FAULT  
LIGHT  
BUTTON  
DIODE  
TO INJECTION  
PUMP SOLENOID  
SAE-400 SEVERE DUTY  
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E-2  
E-2  
THEORY OF OPERATION  
FIGURE E.2 - ALTERNATOR OPERATION  
ELECTRODE  
TERMINAL  
---  
OUTPUT  
CONTROL  
MIN  
MAX  
(OFF)  
AC  
AC  
(-)  
(+)  
REMOTE  
RHEOSTAT  
LOCAL  
RHEOSTAT  
POLARITY  
SWITCH  
(JOB SELECTOR)  
THERMOSTART  
BUTTON  
TO HOUR METER  
FLASHING  
RESISTOR  
RESISTOR AND  
DIODE  
(+)  
(-)  
SHUNT COILS  
SERIES COILS  
THERMOSTAT  
TO IDLE / ENGINE  
PROTECTION BOARD  
INJECTION  
PUMP  
EXCITER  
WINDING  
SOLENOID  
SYSTEM  
(-)  
(+)  
TO IDLE/ENGINE  
GENERATOR  
ARMATURE  
EXCITER  
ROTOR  
PROT. BOARD  
DIESEL  
ENGINE  
AUXILIARY  
POWER  
S
T
A
R
T
E
R
WINDINGS  
INTERPOLE COILS  
STARTER  
OIL  
SOLENOID  
PRESSURE  
SWITCH  
TEMP  
SWITCH  
IDLE  
IDLE SWITCH  
RUN/STOP  
SWITCH  
SOLENOID  
115 VAC  
RECEPTACLES  
230 VAC  
RECEPTACLES  
IDLE / ENGINE  
HOUR  
METER  
PROTECTION BOARD  
AMMETER  
WORK  
TERMINAL  
TO  
FLASHING  
RESISTOR  
AND  
ENGINE  
TO ALTERNATOR  
FLASH/SENSE  
START  
FAULT  
LIGHT  
BUTTON  
DIODE  
TO INJECTION  
PUMP SOLENOID  
ENGINE STARTING AND PROTEC-  
TION  
Turning on the run/stop switch supplies 12VDC power  
to idler/engine protection PC board. During the first  
minute after the switch is placed in the on position,  
power is supplied to the Fuel solenoid, the hour meter,  
and flashing circuits for the engine alternator and the  
exciter alternator. The engine should be started during  
this first minute.  
The machine 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 that routes power from the battery  
to the starting terminal of the starter solenoid. The  
starter will crank the engine even if the run/stop switch  
is in the off position.  
After one minute, the PC board will begin to monitor  
the oil pressure switch, cooling system temp switch,  
and the engine alternator. If a fault is detected in any  
of these systems, the engine fault light will come on  
and the engine will be shut down by shutting off the  
power to the fuel solenoid. These systems signal a  
fault by connecting the sense lead to chassis ground.  
If the engine fault light turns on, the engine protection  
system must be reset by turning the run/stop switch off,  
then on again before attempting to restart the engine.  
NOTE: Unshaded areas of Block Logic  
Diagram are the subject of discussion  
SAE-400 SEVERE DUTY  
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E-3  
E-3  
THEORY OF OPERATION  
FIGURE E.2 - ENGINE STARTING AND PROTECTION  
ELECTRODE  
TERMINAL  
---  
OUTPUT  
CONTROL  
MIN  
MAX  
(OFF)  
AC  
AC  
(-)  
(+)  
REMOTE  
RHEOSTAT  
LOCAL  
RHEOSTAT  
POLARITY  
SWITCH  
(JOB SELECTOR)  
THERMOSTART  
BUTTON  
TO HOUR METER  
FLASHING  
RESISTOR  
RESISTOR AND  
DIODE  
(+)  
(-)  
SHUNT COILS  
SERIES COILS  
THERMOSTAT  
TO IDLE / ENGINE  
PROTECTION BOARD  
INJECTION  
PUMP  
EXCITER  
WINDING  
SOLENOID  
SYSTEM  
(-)  
(+)  
TO IDLE/ENGINE  
GENERATOR  
ARMATURE  
EXCITER  
ROTOR  
PROT. BOARD  
DIESEL  
ENGINE  
AUXILIARY  
POWER  
S
T
A
R
T
E
R
WINDINGS  
INTERPOLE COILS  
STARTER  
OIL  
SOLENOID  
PRESSURE  
SWITCH  
TEMP  
SWITCH  
IDLE  
IDLE SWITCH  
RUN/STOP  
SWITCH  
SOLENOID  
115 VAC  
RECEPTACLES  
230 VAC  
RECEPTACLES  
IDLE / ENGINE  
HOUR  
METER  
PROTECTION BOARD  
AMMETER  
WORK  
TERMINAL  
TO  
FLASHING  
RESISTOR  
AND  
ENGINE  
TO ALTERNATOR  
FLASH/SENSE  
START  
FAULT  
LIGHT  
BUTTON  
DIODE  
TO INJECTION  
PUMP SOLENOID  
AUTOMATIC ENGINE IDLE SYSTEM  
The automatic idle circuitry on the PC board uses a  
magnetic reed switch to sense weld current and a  
toroidal current transformer to sense auxiliary current.  
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.  
The automatic idle system reduces the engine RPM  
when there is no electrical demand on the machine.  
When an arc is struck, or a load of 100 Watts or greater  
is applied to the auxiliary output, the engine speed will  
immediately increase to high RPM. When the load is  
released, the engine continues to run at high RPM for  
about 12 seconds. If a load is re-applied during this  
time, the machine will continue to operate at high RPM.  
If no load is applied, the engine RPM is reduced to idle  
speed.  
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 load on any  
of the outputs, and continues to open and close the  
solenoid’s ground path.  
The automatic idle system functions by energizing a  
solenoid, which pulls the engine speed control to a pre-  
set low idle RPM position. When this solenoid is de-  
energized, the engine speed is controlled by the gov-  
ernor which maintains the engine RPM at the specified  
high RPM setting. The solenoid is supplied with  
+12VDC power whenever the idle switch is in the auto  
If the machine had been operating at low idle and the  
idle switch is moved from auto to high, the engine RPM  
will increase immediately. If the switch is moved from  
high to auto, the engine RPM may be reduced imme-  
diately or it could take up to 12 seconds for the idle cir-  
cuitry on the PC board to activate and engage the sole-  
noid.  
position.  
It is activated when circuitry on the  
Idler/engine shutdown PC board completes the sole-  
noid’s path to chassis ground.  
NOTE: Unshaded areas of Block Logic  
Diagram are the subject of discussion  
SAE-400 SEVERE DUTY  
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E-4  
E-4  
THEORY OF OPERATION  
FIGURE E.2 - GENERAL DESCRIPTION  
ELECTRODE  
TERMINAL  
OUTPUT  
CONTROL  
MIN  
MAX  
(OFF)  
AC  
AC  
(-)  
(+)  
REMOTE  
RHEOSTAT  
LOCAL  
RHEOSTAT  
POLARITY  
SWITCH  
(JOB SELECTOR)  
THERMOSTART  
BUTTON  
TO HOUR METER  
FLASHING  
RESISTOR  
RESISTOR AND  
DIODE  
(+)  
(-)  
SHUNT COILS  
SERIES COILS  
THERMOSTAT  
TO IDLE / ENGINE  
PROTECTION BOARD  
INJECTION  
PUMP  
EXCITER  
WINDING  
SOLENOID  
SYSTEM  
(-)  
(+)  
TO IDLE/ENGINE  
GENERATOR  
ARMATURE  
EXCITER  
ROTOR  
PROT. BOARD  
DIESEL  
ENGINE  
AUXILIARY  
POWER  
S
T
A
R
T
E
R
WINDINGS  
INTERPOLE COILS  
STARTER  
OIL  
SOLENOID  
PRESSURE  
SWITCH  
TEMP  
SWITCH  
IDLE  
IDLE SWITCH  
RUN/STOP  
SWITCH  
SOLENOID  
115 VAC  
RECEPTACLES  
230 VAC  
RECEPTACLES  
IDLE / ENGINE  
HOUR  
METER  
PROTECTION BOARD  
AMMETER  
WORK  
TERMINAL  
TO  
FLASHING  
RESISTOR  
AND  
ENGINE  
TO ALTERNATOR  
FLASH/SENSE  
START  
FAULT  
LIGHT  
BUTTON  
DIODE  
TO INJECTION  
PUMP SOLENOID  
EXCITER/AUXILIARY ALTERNATOR  
OPERATION  
The exciter alternator is the smaller power generator  
that is located at the end of the main welding genera-  
tor. It provides power to energize the rotor, the shunt  
fields of the main welding generator and about 3 KVA  
of 120/230 volts, 60 Hz. for auxiliary power.  
Building output:  
The flashing current produces a weak magnetic field in  
the rotor, which is coupled to the now running engine.  
This rotating magnetic field begins to generate AC out-  
put from all of the 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.  
Flashing:  
The exciter alternator requires that DC power be  
applied to the slip rings to start the power generation  
process. This DC power is often referred to as  
“Flashing” voltage, and originates at the battery. This  
voltage is applied through the Idler/Engine Protection  
PC Board, whenever the fuel solenoid is open and the  
hour meter is running.  
This process of strengthening the magnetic field  
through feedback from the exciter winding continues to  
increase the output of the alternator until the design  
voltage is reached.  
The field voltage is now considerably higher than the  
flashing voltage that was used to start the generating  
process. The diode in the flashing circuit now blocks  
that higher field voltage from intruding into the 12VDC  
battery system and the machine chassis.  
The flashing current passes through a blocking diode  
and current limiting resistor before being applied to the  
rotor field winding through the positive brush and slip  
ring. The current then passes out of the negative slip  
ring and brush, through two diodes, and back to the  
battery through a chassis ground connection.  
(continued on next page)  
NOTE: Unshaded areas of Block Logic  
Diagram are the subject of discussion  
SAE-400 SEVERE DUTY  
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E-5  
E-5  
THEORY OF OPERATION  
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’s current sensor.  
SAE-400 SEVERE DUTY  
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E-6  
E-6  
THEORY OF OPERATION  
FIGURE E.2 - GENERAL DESCRIPTION  
ELECTRODE  
TERMINAL  
OUTPUT  
CONTROL  
MIN  
MAX  
(OFF)  
AC  
AC  
(-)  
(+)  
REMOTE  
RHEOSTAT  
LOCAL  
RHEOSTAT  
POLARITY  
SWITCH  
(JOB SELECTOR)  
THERMOSTART  
BUTTON  
TO HOUR METER  
FLASHING  
RESISTOR  
RESISTOR AND  
DIODE  
(+)  
(-)  
SHUNT COILS  
SERIES COILS  
THERMOSTAT  
TO IDLE / ENGINE  
PROTECTION BOARD  
INJECTION  
PUMP  
EXCITER  
WINDING  
SOLENOID  
SYSTEM  
(-)  
(+)  
TO IDLE/ENGINE  
GENERATOR  
ARMATURE  
EXCITER  
ROTOR  
PROT. BOARD  
DIESEL  
ENGINE  
AUXILIARY  
POWER  
S
T
A
R
T
E
R
WINDINGS  
INTERPOLE COILS  
STARTER  
OIL  
SOLENOID  
PRESSURE  
SWITCH  
TEMP  
SWITCH  
IDLE  
IDLE SWITCH  
RUN/STOP  
SWITCH  
SOLENOID  
115 VAC  
RECEPTACLES  
230 VAC  
RECEPTACLES  
IDLE / ENGINE  
HOUR  
METER  
PROTECTION BOARD  
AMMETER  
WORK  
TERMINAL  
TO  
FLASHING  
RESISTOR  
AND  
ENGINE  
TO ALTERNATOR  
FLASH/SENSE  
START  
FAULT  
LIGHT  
BUTTON  
DIODE  
TO INJECTION  
PUMP SOLENOID  
WELDING GENERATOR OPERA-  
TION  
Overview:  
The power used to excite the generator starts out as  
AC current produced by the exciter/auxiliary alternator.  
This AC current passes through a remote/local switch  
and then through either a remote or the front panel  
mounted 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.  
The welding generator is coupled directly to the engine  
and produces the DC current required for welding and  
arc gouging. The welding power is induced in the wind-  
ings of the armature when it spins in a magnetic field.  
The power produced in the armature is converted to  
direct current (DC) by a commutator and a set of car-  
bon brushes, which are then connected to the interpole  
coils, the series coils, and the reactor assembly. The  
weld current is controlled by varying the field (Job  
Selector) and the reactor (Current Control) setting,  
using the front panel control knobs.  
Reversing the polarity of the field also reverses the  
polarity of the weld current. When the polarity switch is  
moved to the neutral position, the shunt coils are dis-  
connected. The resulting collapse of the magnetic field  
around these coils can produce a very high induced  
voltage. A 500 Ohm resistor is connected in parallel  
with the shunt coil set to reduce this voltage to a level  
that is within the limits of the insulation used. It also  
helps reduce arcing and damage to the polarity switch.  
Excitation and field control:  
Before any welding current can be produced, there  
must be a magnetic field in which the armature can  
spin. Creating this magnetic field is often described as  
exciting the generator, and is accomplished by passing  
controlled DC current through two shunt coils in the  
generator stator.  
NOTE: Unshaded areas of Block Logic  
Diagram are the subject of discussion  
SAE-400 SEVERE DUTY  
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E-7  
E-7  
THEORY OF OPERATION  
FIGURE E.2 - GENERAL DESCRIPTION  
ELECTRODE  
TERMINAL  
OUTPUT  
CONTROL  
MIN  
MAX  
(OFF)  
AC  
AC  
(-)  
(+)  
REMOTE  
RHEOSTAT  
LOCAL  
RHEOSTAT  
POLARITY  
SWITCH  
(JOB SELECTOR)  
THERMOSTART  
BUTTON  
TO HOUR METER  
FLASHING  
RESISTOR  
RESISTOR AND  
DIODE  
(+)  
(-)  
SHUNT COILS  
SERIES COILS  
THERMOSTAT  
TO IDLE / ENGINE  
PROTECTION BOARD  
INJECTION  
PUMP  
EXCITER  
WINDING  
SOLENOID  
SYSTEM  
(-)  
(+)  
TO IDLE/ENGINE  
GENERATOR  
ARMATURE  
EXCITER  
ROTOR  
PROT. BOARD  
DIESEL  
ENGINE  
AUXILIARY  
POWER  
S
T
A
R
T
E
R
WINDINGS  
INTERPOLE COILS  
STARTER  
OIL  
SOLENOID  
PRESSURE  
SWITCH  
TEMP  
SWITCH  
IDLE  
IDLE SWITCH  
RUN/STOP  
SWITCH  
SOLENOID  
115 VAC  
RECEPTACLES  
230 VAC  
RECEPTACLES  
IDLE / ENGINE  
HOUR  
METER  
PROTECTION BOARD  
AMMETER  
WORK  
TERMINAL  
TO  
FLASHING  
RESISTOR  
AND  
ENGINE  
TO ALTERNATOR  
FLASH/SENSE  
START  
FAULT  
LIGHT  
BUTTON  
DIODE  
TO INJECTION  
PUMP SOLENOID  
WELDING GENERATOR OPERA-  
TION (Continued)  
The brushes contact the commutator at precise points  
around its circumference and are positioned so that  
they will conduct current only from windings that are  
producing maximum output at the correct polarity.  
Producing weld current:  
Weld current is produced in the armature windings  
when it spins in the magnetic field produced by the  
excitation process described above. The 64 Ohm rheo-  
stat in the excitation circuit varies the strength of the  
field. A stronger field will produce greater weld output;  
a weaker field will produce less.  
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.  
As the windings in the armature pass through the mag-  
netic field, current flows, first in one direction, then the  
other. This alternating current flow is converted to  
direct current (DC) and connected to the remaining  
generator circuitry through a commutator and a system  
of 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 Control dials on the control panel of  
the SAE-400 machine.  
The commutator is a cylindrical structure made up of  
copper conductor bars and insulating materials that  
keep each bar isolated from the other bars and from  
the armature shaft. Each bar is connected to the end  
of an armature winding.  
Job Selector:  
The Job Selector handle rotates the 64 Ohm rheostat  
described in the section on excitation and field control.  
This control has a significant effect on the open circuit  
voltage (OCV) of the weld output.  
NOTE: Unshaded areas of Block Logic  
Diagram are the subject of discussion  
SAE-400 SEVERE DUTY  
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E-8  
E-8  
THEORY OF OPERATION  
FIGURE E.2 - GENERAL DESCRIPTION  
ELECTRODE  
TERMINAL  
OUTPUT  
CONTROL  
MIN  
MAX  
(OFF)  
AC  
AC  
(-)  
(+)  
REMOTE  
RHEOSTAT  
LOCAL  
RHEOSTAT  
POLARITY  
SWITCH  
(JOB SELECTOR)  
THERMOSTART  
BUTTON  
TO HOUR METER  
FLASHING  
RESISTOR  
RESISTOR AND  
DIODE  
(+)  
(-)  
SHUNT COILS  
SERIES COILS  
THERMOSTAT  
TO IDLE / ENGINE  
PROTECTION BOARD  
INJECTION  
PUMP  
EXCITER  
WINDING  
SOLENOID  
SYSTEM  
(-)  
(+)  
TO IDLE/ENGINE  
GENERATOR  
ARMATURE  
EXCITER  
ROTOR  
PROT. BOARD  
DIESEL  
ENGINE  
AUXILIARY  
POWER  
S
T
A
R
T
E
R
WINDINGS  
INTERPOLE COILS  
STARTER  
OIL  
SOLENOID  
PRESSURE  
SWITCH  
TEMP  
SWITCH  
IDLE  
IDLE SWITCH  
RUN/STOP  
SWITCH  
SOLENOID  
115 VAC  
RECEPTACLES  
230 VAC  
RECEPTACLES  
IDLE / ENGINE  
HOUR  
METER  
PROTECTION BOARD  
AMMETER  
WORK  
TERMINAL  
TO  
FLASHING  
RESISTOR  
AND  
ENGINE  
TO ALTERNATOR  
FLASH/SENSE  
START  
FAULT  
LIGHT  
BUTTON  
DIODE  
TO INJECTION  
PUMP SOLENOID  
WELDING GENERATOR OPERA-  
TION (Continued)  
Reactor Assembly:  
The reactor assembly functions like a specialized, high  
current rheostat, and is connected in parallel with the  
series coils of the generator. At the very minimum set-  
ting the reactor is electrically open, forcing all of the  
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.  
Current Control:  
The Current Control handle turns a rotor inside the  
reactor assembly. This reactor assembly functions  
together with the generator’s series coils to regulate  
the output current and produce the drooping volt/amp  
curve that is so important to a constant current welding  
source. This current control has almost no effect on  
the OCV.  
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 even more current to  
bypass the series coils. When the current control is set  
to maximum, the reactor resistance is at minimum, and  
nearly all of the current passes through the reactor.  
Because the current passing through the reactor is not  
reduced by the bucking action of the series coils, weld  
current is increased.  
Series coils and reactor:  
Current from two of the four sets of brushes is routed  
through the generator’s series coils and the reactor  
assembly before being connected to one of the weld  
output terminals. These series coils are wound and  
arranged in such a way as to reduce or buck the cur-  
rent flowing from the armature. Because the series  
coils do not reduce the weld output until current is flow-  
ing, OCV is not reduced, and starting the arc is easier.  
NOTE: Unshaded areas of Block Logic  
Diagram are the subject of discussion  
SAE-400 SEVERE DUTY  
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E-9  
E-9  
THEORY OF OPERATION  
FIGURE E.2 - GENERAL DESCRIPTION  
ELECTRODE  
TERMINAL  
OUTPUT  
CONTROL  
MIN  
MAX  
(OFF)  
AC  
AC  
(-)  
(+)  
REMOTE  
RHEOSTAT  
LOCAL  
RHEOSTAT  
POLARITY  
SWITCH  
(JOB SELECTOR)  
THERMOSTART  
BUTTON  
TO HOUR METER  
FLASHING  
RESISTOR  
RESISTOR AND  
DIODE  
(+)  
(-)  
SHUNT COILS  
SERIES COILS  
THERMOSTAT  
TO IDLE / ENGINE  
PROTECTION BOARD  
INJECTION  
PUMP  
EXCITER  
WINDING  
SOLENOID  
SYSTEM  
(-)  
(+)  
TO IDLE/ENGINE  
GENERATOR  
ARMATURE  
EXCITER  
ROTOR  
PROT. BOARD  
DIESEL  
ENGINE  
AUXILIARY  
POWER  
S
T
A
R
T
E
R
WINDINGS  
INTERPOLE COILS  
STARTER  
OIL  
SOLENOID  
PRESSURE  
SWITCH  
TEMP  
SWITCH  
IDLE  
IDLE SWITCH  
RUN/STOP  
SWITCH  
SOLENOID  
115 VAC  
RECEPTACLES  
230 VAC  
RECEPTACLES  
IDLE / ENGINE  
HOUR  
METER  
PROTECTION BOARD  
AMMETER  
WORK  
TERMINAL  
TO  
FLASHING  
RESISTOR  
AND  
ENGINE  
TO ALTERNATOR  
FLASH/SENSE  
START  
FAULT  
LIGHT  
BUTTON  
DIODE  
TO INJECTION  
PUMP SOLENOID  
WELDING GENERATOR OPERA-  
TION (Continued)  
Interpole coils:  
Armature current from the remaining two sets of brush-  
es is routed through four interpole coils, before being  
connected to the weld output terminal. These coils are  
narrower than the shunt and series coils, and are locat-  
ed in the generator stator between them. Their purpose  
is to reduce distortion of the magnetic field.  
The magnetic field generated by the the shunt coils will  
become distorted when current is drawn from the  
armature. This distortion will increase as the current  
flow increases. The interpole coils are connected and  
arranged to counteract this magnetic distortion. If not  
corrected, the distortion would cause reduced output  
and excessive sparking on the commutator.  
NOTE: Unshaded areas of Block Logic  
Diagram are the subject of discussion  
SAE-400 SEVERE DUTY  
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E-10  
E-10  
NOTES  
SAE-400 SEVERE DUTY  
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F-1  
F-1  
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR  
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1  
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2  
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3  
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4  
Test Procedures  
Engine RPM Adjustment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-21  
Brush And Slip Ring Service Procedure (Exciter / Auxiliary Power Alternator) . . . . . . . . . . . . . . . . . .F-25  
Exciter Rotor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29  
Exciter Rotor Resistance And Ground Test (Exciter / Auxiliary Power Alternator . . . . . . . . . . . . . . . . F-33  
Flashing Voltage Test (Engine Not Running) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 Procedure . . . . . . . . . . . . . . . . . . . .F-59  
Engine Protection System Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-65  
Engine Alternator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-69  
Engine Fuel System Voltage Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-73  
Removal and Replacement Procedures  
Alternator Rotor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-77  
Alternator Stator Removal And Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-81  
Generator Frame Removal And Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-85  
Generator Armature Removal And Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-87  
Retest And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-89  
SAE-400 SEVERE DUTY  
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F-2  
F-2  
TROUBLESHOOTING AND REPAIR  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and Repair should only be performed by Lincoln Electric Factory Trained  
Personnel. Unauthorized repairs performed on this equipment may result in danger to  
the technician and machine operator and will invalidate your factory warranty. For your  
safety and to avoid Electrical Shock, please observe all safety notes and precautions  
detailed throughout this manual.  
---------------------------------------------------------------------------------------------------------------------------  
Step 3. RECOMMENDED  
This Troubleshooting Guide is provided to  
help you locate and repair possible machine  
malfunctions. Simply follow the three-step  
procedure listed below.  
COURSE OF ACTION  
The last column labeled “Recommended  
Course of Action” lists the most likely com-  
ponents that may have failed in your  
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.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled “PROBLEM  
(SYMPTOMS)”. This column describes pos-  
sible symptoms that the machine may exhib-  
it. Find the listing that best describes the  
symptom that the machine is exhibiting.  
Symptoms are grouped into the following  
categories: output problems, function prob-  
lems, wire feeding problems, and welding  
problems.  
All of the referenced test procedures  
referred to in the Troubleshooting Guide are  
described in detail at the end of this chapter.  
Refer to the Troubleshooting and Repair  
Table of Contents to locate each specific  
Test Procedure. All of the specified test  
points, components, terminal strips, etc. can  
be found on the referenced electrical wiring  
diagrams and schematics. Refer to the  
Electrical Diagrams Section Table of  
Contents to locate the appropriate diagram.  
Step 2. PERFORM EXTERNAL TESTS.  
The second column labeled “POSSIBLE  
AREAS OF MISADJUSTMENT(S)” lists the  
obvious external possibilities that may con-  
tribute to the machine symptom. Perform  
these tests/checks in the order listed. In  
general, these tests can be conducted with-  
out removing the case wrap-around cover.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the  
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting  
assistance before you proceed. Call 1-888-935-3877.  
-----------------------------------------------------------------------------------------------------------------------------------  
SAE-400 SEVERE DUTY  
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F-3  
F-3  
TROUBLESHOOTING AND REPAIR  
PC BOARD TROUBLESHOOTING PROCEDURES  
- 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.  
WARNING  
ELECTRIC SHOCK  
can kill.  
•
Have an electrician install and  
service this equipment. Turn the  
input power OFF at the fuse box  
before working on equipment. Do  
not touch electrically hot parts.  
- If the PC board uses protective shorting jumpers,  
don’t remove them until installation is complete.  
- If you return a PC board to The Lincoln Electric  
Company for credit, it must be in the static-shielding  
bag. This will prevent further damage and allow prop-  
er failure analysis.  
CAUTION  
Sometimes machine failures appear to be due to PC  
board failures. These problems can sometimes be  
traced to poor electrical connections. To avoid prob-  
lems when troubleshooting and replacing PC boards,  
please use the following procedure:  
4. Test the machine to determine if the failure  
symptom has been corrected by the  
replacement PC board.  
NOTE: It is desirable to have a spare (known good)  
PC board available for PC board troubleshooting.  
1. Determine to the best of your technical ability  
that the PC board is the most likely component  
causing the failure symptom.  
NOTE: Allow the machine to heat up so that all  
electrical components can reach their operating  
temperature.  
2. Check for loose connections at the PC board  
to assure that the PC board is properly  
connected.  
5. Remove the replacement PC board and  
substitute it with the original PC board to  
recreate the original problem.  
3. If the problem persists, replace the suspect PC  
board using standard practices to avoid static  
electrical damage and electrical shock. Read  
the warning inside the static resistant bag and  
perform the following procedures:  
a. If the original problem does not reappear by  
substituting the original board, then the PC  
board was not the problem. Continue to look  
for bad connections in the control wiring  
harness, junction blocks, and terminal strips.  
PC board can be damaged by static electricity.  
b. If the original problem is recreated by the  
substitution of the original board, then the PC  
board was the problem. Reinstall the  
replacement PC board and test the machine.  
- Remove your body’s static  
charge before opening the static-  
shielding bag. Wear an anti-static  
wrist strap. For safety, use a 1  
Meg ohm resistive cord connected  
6. Always indicate that this procedure was  
followed when warranty reports are to be  
submitted.  
to  
a
grounded part of the  
ATTENTION  
Static-Sensitive  
Devices  
equipment frame.  
NOTE: Following this procedure and writing on the  
warranty report, “INSTALLED AND SWITCHED PC  
BOARDS TO VERIFY PROBLEM,” will help avoid  
denial of legitimate PC board warranty claims.  
- If you don’t have a wrist strap,  
touch an un-painted, grounded,  
part of the equipment frame. Keep  
touching the frame to prevent  
static build-up. Be sure not to  
touch any electrically live parts at  
the same time.  
Handle only at  
Static-Safe  
Workstations  
- Tools which come in contact with the PC board must  
be either conductive, anti-static or static-dissipative.  
SAE-400 SEVERE DUTY  
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F-4  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-4  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
(SYMPTOMS)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Make sure the engine is  
operating at the correct high idle  
speed.  
Both the weld and auxiliary  
output voltages are low  
Perform the Engine RPM  
Adjustment Test.  
Perform the Brush and Slip  
Make sure that no load is  
connected to either the weld or  
auxiliary outputs.  
Ring Service Procedure.  
Perform the Exciter Rotor  
Voltage Test.  
Perform Exciter Rotor  
Resistance and Ground Test.  
Check that the electrode polarity  
switch is not in the off position,  
and that the remote/local switch  
is in the local control position.  
Check that the auxiliary power  
circuit breakers and GFCIs (if so  
equipped) are not tripped.  
There is no, or very low weld  
output, and no auxiliary output.  
Perform the Brush and Slip  
Ring Service Procedure.  
Perform the Exciter Rotor  
Voltage Test.  
Perform the Exciter Rotor  
Resistance and Ground Test.  
NOTE: GFCIs will not reliably  
reset, unless engine is operating  
at high idle RPM.  
Check all leads and cables for  
damaged or poor connections.  
There is no, or very low weld  
output voltage. The auxiliary  
output is normal.  
Check the polarity switch; make  
sure it is not in the off position.  
Perform the Shunt Field Coil  
Resistance and Ground Test.  
Check that the remote/local  
switch is positioned correctly.  
Perform the Shunt Field Circuit  
Voltage Test.  
If a remote current control is  
being used, try switching to  
local control. The remote  
current control may be faulty.  
Perform the Welding Generator  
Brush and Commutator  
Inspection and Service  
Procedure.  
Check all leads and cables for  
damaged or poor connections.  
Check for damaged or poor  
connections at the brush  
holders, series and interpole  
coils, weld output control unit,  
weld output terminals, and all  
the conductors connecting these  
components.  
The Armature may be faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
SAE-400 SEVERE DUTY  
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F-5  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-5  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
(SYMPTOMS)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
There is no auxiliary voltage,  
weld output is normal.  
Check that the auxiliary power  
Check for auxiliary voltage at the  
receptacle input terminals, if  
normal voltage is present,  
replace receptacle.  
circuit breakers are not tripped.  
If the machine is equipped with a  
ground fault circuit interrupter  
(GFCI), it may be tripped or  
defective.  
Check for auxiliary voltage at the  
connections closest to the  
exciter stator windings. See  
wiring diagram.  
NOTE: GFCIs will not reliably  
reset, unless engine is operating  
at high idle RPM.  
•
•
If normal voltage is present,  
check the wiring and circuit  
breakers between the test  
points and the receptacle.  
Repair or replace any  
Check all leads and cables for  
damaged or poor connections.  
defective parts or wiring.  
If normal voltage is not  
present, check for damaged  
conductors between the test  
points and the winding. If the  
conductors are good, the  
stator is defective.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
SAE-400 SEVERE DUTY  
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F-6  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-6  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
(SYMPTOMS)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The weld output varies  
abnormally. Auxiliary voltage is  
normal.  
Check welding cables for  
Check and, if necessary, perform  
the Brush and Slip Ring  
Service Procedure.  
damaged or poor connections.  
Welding cable may be  
excessively long, too small, or  
coiled. Try using a set of short  
test cables of adequate size.  
Perform the Welding Generator  
Brush and Commutator  
Inspection and Service  
Procedure.  
If a remote current control is  
being used, try switching to local  
control. The remote current  
control may be faulty.  
Perform the Engine RPM  
Adjustment Test.  
Check all the large weld current  
carrying leads inside the  
machine for damaged  
The engine may not be  
maintaining steady RPM. Make  
sure there is an adequate supply  
of clean, fresh fuel. Replace  
fuel filters if necessary. Have  
engine serviced by a qualified  
engine technician.  
conductors, insulation, and poor  
connections.  
Perform the Output Control  
Unit Inspection and Service  
Procedure.  
Check the wiring that connects  
the exciter, diode bridges,  
rheostat, remote/local switch,  
polarity switch, and the shunt  
coils. Check for damaged  
conductors, insulation, and  
connections.  
Check Job Selector rheostat,  
replace if necessary.  
Check remote/local switch.  
Replace if necessary  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
SAE-400 SEVERE DUTY  
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F-7  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-7  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
(SYMPTOMS)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The weld output varies  
abnormally. Auxiliary 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 Adjustment Procedure  
if necessary.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-8  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-8  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
(SYMPTOMS)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The weld output is considerably  
less than indicated on the dials.  
Auxiliary voltage is normal.  
Check welding cables for  
Perform the Engine RPM  
damaged or poor connections.  
Adjustment Test.  
Welding cable may be  
Perform the Welding Generator  
Brush and Commutator  
Inspection and Service  
Procedure.  
excessively long, too small, or  
coiled. Try using a set of short  
test cables of adequate size.  
If a remote current control is  
being used, try switching to local  
control. The remote current  
control may be faulty.  
Perform the Brush and Slip  
Ring Service Procedure.  
Perform the Shunt Field Coil  
Resistance and Ground Test.  
The engine RPM may low. Make  
sure there is an adequate supply  
of clean, fresh fuel. Replace  
fuel filters if necessary. Have  
engine serviced by a qualified  
engine technician.  
Perform the “Dead Short”,  
“First Step”, and “Open  
Reactor” Tests. If necessary,  
perform the Output Control  
Unit Inspection and Service  
Procedure.  
Perform the Exciter Rotor  
Resistance and Ground Test.  
Check all the large weld current  
carrying leads inside the  
machine for damaged  
conductors, damaged insulation,  
and poor connections.  
Check the wiring that connects  
the exciter, diode bridges,  
rheostat, remote/local switch,  
polarity switch, and the shunt  
coils. Check for damaged  
conductors, insulation, and  
connections.  
Check Job Selector rheostat,  
replace if necessary.  
Check remote/local switch.  
Replace if necessary  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-9  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-9  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
(SYMPTOMS)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The weld output is considerably  
less than indicated on the dials.  
Auxiliary voltage is normal.  
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.  
(continued)  
Verify that the rocker is  
positioned correctly, according to  
the factory drill mark. If  
necessary, perform the Rocker  
Adjustment Procedure.  
The weld output is considerably  
higher than indicated on the  
dials. Auxiliary voltage is  
normal.  
If a remote current control is  
being used, try switching to local  
control. The remote current  
control may be faulty.  
Verify that the rocker is  
positioned correctly, according to  
the factory drill mark.  
Perform the Dead Short, First  
Step, and Open Reactor Tests.  
Perform the Exciter Rotor  
Resistance and Ground Test.  
Perform the Shunt Field Coil  
Resistance and Ground Test.  
Perform the Rocker Adjustment  
Procedure.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-10  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-10  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
(SYMPTOMS)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The welding arc is loud and  
spatters excessively.  
The weld current or voltage  
The engine RPM may be  
incorrect; perform the Engine  
RPM Adjustment Test.  
settings may be incorrect.  
The polarity may be incorrect for  
the process in use. Make sure  
that the actual polarity of the  
output studs is what the Polarity  
Switch indicates.  
Perform the Brush and Slip  
Ring Service Procedure.  
Perform the Welding generator  
Brush and Commutator  
Inspection and Service  
Procedure.  
If a remote current control is  
being used, try switching to local  
control. The remote current  
control may be faulty.  
Perform the Dead Short, First  
Step, and Open Reactor Tests.  
Perform the Exciter Rotor  
Resistance and Ground Test.  
Perform the Shunt Field Coil  
Resistance and Ground Test.  
Check that the rocker is aligned  
to the factory drill mark, and  
perform the Rocker Adjustment  
Procedure if necessary  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-11  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-11  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
(SYMPTOMS)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The welding arc frequently “pops  
out”. Welding seems otherwise  
normal and auxiliary output  
voltage appears normal.  
The Job selector rheostat may  
The engine RPM may be  
incorrect; perform the Engine  
RPM Adjustment Test.  
be set too low.  
If a remote control is being used,  
try switching to local control.  
The remote control unit may be  
faulty.  
Perform the Brush and Slip  
Ring Service Procedure.  
Perform the Welding Generator  
Brush and Commutator  
Inspection and Service  
Procedure.  
Check welding cables for  
damaged or poor connections.  
Welding cable may be  
excessively long, too small, or  
coiled. Try using a set of short  
test cables of adequate size.  
Perform the Output control unit  
Inspection and Service  
Procedure.  
Perform the Exciter Rotor  
Voltage Test.  
Perform the Shunt Field Circuit  
Voltage Test.  
Check that the rocker is aligned  
to the factory drill mark, and  
perform the Rocker Adjustment  
Procedure if necessary.  
The batteries may be  
discharged. Check, and if  
necessary, charge or replace the  
batteries.  
Check for battery voltage where  
lead 235 connects to the starter  
solenoid, while holding in the  
start button.  
The engine will not crank when  
the start button is pressed.  
The battery cables or battery  
connections may be loose or  
corroded. Service the battery  
terminals.  
•
If no voltage is present, check  
the connections and wiring  
connecting the starter  
solenoid, the ammeter, and  
the start push button switch.  
(See the wiring diagram) If  
the wiring and connections  
are good, replace the push  
button switch.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-12  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-12  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
(SYMPTOMS)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The engine will not crank when  
the start button is pressed.  
•
If voltage is present, check  
that the negative battery  
terminal is properly connected  
to the engine block. If the  
battery is properly connected,  
the starter/solenoid is  
(continued)  
defective and should be  
serviced or replaced.  
The engine cranks when the  
start button is pressed, but will  
not start.  
Perform the Engine Fuel  
Make sure the run/stop switch is  
in the run position.  
System Voltage Tests.  
The run/stop switch may have  
been left in the run position for  
more that 30 seconds (60  
seconds for some models).  
Move switch to the stop position,  
then after a few seconds, 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 fuel  
system. See the engine  
manufacturer’s manual and  
bleed all air from the fuel  
system.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-13  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-13  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
(SYMPTOMS)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The engine starts normally, but  
shuts down after running for  
several seconds.  
The oil pressure may be low.  
Check the oil level and add oil  
as needed. If necessary, contact  
the engine manufacturer, or a  
qualified engine specialist to  
determine the cause of the low  
oil pressure condition, and make  
any required adjustments or  
repairs.  
The idle/engine protection PC  
board, alternator, oil pressure  
switch, or engine coolant  
temperature switch may be  
faulty. Perform the Engine  
Protection System Test.  
The engine alternator belt may  
be loose or broken. Replace the  
belt and/or adjust the belt  
tension.  
The engine may be overheated.  
Contact the engine  
manufacturer, or a qualified  
engine specialist to determine  
the cause of the overheat  
condition, and make any  
required adjustments or repairs.  
Perform the Engine RPM  
Check that there is an adequate  
supply of fresh clean fuel, and  
that the fuel shut-off valve is fully  
open.  
The engine will not develop full  
power.  
Adjustment Test.  
There may be internal problems  
with the engine. Contact the  
engine manufacturer or a  
qualified engine repair  
technician.  
Check the fuel and air filters,  
replace if necessary.  
Check the voltage at the  
primary fuel solenoid. If the  
voltage drops to zero when the  
switch is turned off, and the  
engine continues to run, there is  
likely a failure in the fuel  
system. Contact the engine  
manufacturer or a qualified  
engine technician.  
The engine will not shut down  
when the run/stop switch is  
moved to the stop position.  
If the voltage remains at the  
solenoid after the switch is  
moved to the stop position, the  
run/stop switch has most likely  
failed.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-14  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-14  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
(SYMPTOMS)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The battery may be faulty.  
Recharge and test the battery.  
Replace it if necessary.  
The battery does not stay  
charged.  
Perform the Engine Alternator  
Test.  
The engine alternator drive belt  
may be loose. Replace and/or  
adjust the belt tension.  
The machine will not idle down  
to low RPM when weld and  
auxiliary loads are removed.  
Make sure the idle switch is in  
the “AUTO IDLE” position.  
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.  
Make sure there is no external  
load on the weld terminals or the  
auxiliary power receptacles.  
Disconnect the weld cables and  
unplug anything that may be  
connected to the auxiliary  
receptacles.  
The machine has normal weld  
and auxiliary output. The engine  
starts and shuts down normally.  
Check that the solenoid can  
freely pull in and solidly seat  
against its internal stop.  
Check for mechanical restrictions  
in the idler solenoid linkage.  
Perform the Engine RPM  
Adjustment Test.  
The idle solenoid may have  
failed. Disconnect the solenoid  
leads and check the resistance  
of the solenoid coil.  
For code 10856, the resistance  
should measure about 8.8 Ohms.  
For codes 11199 and 11408, the  
resistance from the black lead to  
the white lead should measure  
about 0.4 Ohms. The resistance  
from the black lead to the red  
lead should be about 15 Ohms.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-15  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-15  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
(SYMPTOMS)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The machine will not idle down  
to low RPM when weld and  
auxiliary loads are removed.  
Check the solenoid for a  
grounded coil; the resistance  
between chassis ground and  
either solenoid lead wire should  
be 500k Ohms (500,000 Ohms)  
minimum.  
The machine has normal weld  
and auxiliary output. The engine  
starts and shuts down normally.  
Apply battery voltage directly to  
the solenoid leads and verify  
that it is operating normally.  
(continued)  
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. Manually  
move the plunger into the  
solenoid. The plunger should  
hold tightly against the internal  
stop and remain in that position  
until the voltage is removed.  
The 2-CR Reed relay may be  
faulty. The reed relay should be  
electrically open if no current is  
flowing in the weld circuit. If  
there is continuity through the  
reed relay when the machine is  
off, it is defective and should be  
replaced.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-16  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-16  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
(SYMPTOMS)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The machine will not idle down  
to low RPM when weld and  
auxiliary loads are removed.  
There may be voltage in the  
toroidal current sensor circuit.  
Unplug the current sensor from  
the PC board. Unplug J2 for  
code 10856, and J32 for codes  
11119 and 11408.  
The machine has normal weld  
and auxiliary output. The engine  
starts and shuts down normally.  
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  
(continued)  
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 AC auxiliary circuit. (See  
wiring diagram)  
If the machine still will not idle  
down, check all wiring connected  
to the solenoid. See the wiring  
diagram. Look for damaged  
wiring, poor connections, dirty or  
corroded terminals, etc. If all of  
the wiring is good, replace the  
PC board.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-17  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-17  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
(SYMPTOMS)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The engine goes to low idle, but  
will not stay at low idle.  
Make sure there are no external  
loads on the weld terminals or  
the auxiliary power receptacles.  
Disconnect the weld cables and  
unplug anything that may be  
connected to the auxiliary  
receptacles.  
The low idle RPM may be too  
low. Perform the Engine Idle  
Adjustment Procedure.  
The machine has normal weld  
and auxiliary output. The engine  
starts and shuts down normally.  
The idle solenoid linkage may be  
out 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 between chassis  
ground and either solenoid lead  
wire should be 500k Ohms  
(500,000 Ohms) minimum.  
There may be a poor or  
intermittent connection in the  
solenoid wiring, or a component  
may be opening while under  
load. Check the idle switch and  
the wiring between the switch,  
the solenoid, and the PC Board.  
Repair or replace any poor  
connections, damaged wiring, or  
faulty components. (See wiring  
diagram)  
The idle/engine protection PC  
board may be faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-18  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-18  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
(SYMPTOMS)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The engine will not go to high  
idle when the idle switch is  
moved to the “High” position.  
The idle system functions  
For code 10856  
The Idle switch may be  
defective, or the insulation on  
Lead #234 may be damaged.  
normally while welding or using  
auxiliary power. The engine  
starts and shuts down normally.  
For codes 11199 and 11408  
The idle switch may be  
defective, or there may be a  
faulty connection between the  
PC board, the idle switch, and  
the chassis ground connection.  
For Code 10856:  
The engine will not go to high  
idle when striking an arc or when  
using auxiliary power. The  
engine goes to high idle, and the  
weld and auxiliary power are  
normal when the idle switch is in  
the “High Idle” position. The  
engine starts, runs, and shuts  
down normally.  
Check that the welding cables  
and the auxiliary power lead  
connections are tight and in  
good condition.  
Wire #231 that connects the  
solenoid to the idle/engine  
protection PC board may be  
grounded. Check for damaged  
insulation and improper  
connections.  
The Idle/Engine Protection PC  
board is probably faulty.  
For Codes 11199 and 11408:  
The Idle/Engine Protection PC  
board is probably faulty.  
The engine will not go to high  
idle when striking an arc. The  
automatic idle system functions  
normally when using auxiliary  
power. Weld and auxiliary  
Check that the welding cables,  
electrode holder, and work  
clamp are tight and in good  
condition.  
The 2 CR Reed Relay, or the  
wiring that connects it to the PC  
board and chassis ground may  
be faulty. The Reed relay  
should close when sufficient  
current is drawn from the weld  
output terminals.  
This may be normal operation if  
the machine has a Constant  
Voltage adapter, and is  
power are normal when the idle  
switch is in the “High Idle”  
position. The engine starts,  
runs, and shuts down normally.  
operating in CV mode. See the  
operator’s manual for the  
Constant Voltage Adapter.  
The Idle/Engine Protection PC  
board may be faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-19  
Observe Safety Guidelines detailed in the beginning of this manual.  
F-19  
TROUBLESHOOTING AND REPAIR  
PROBLEMS  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
(SYMPTOMS)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The engine will not go to high  
idle when using auxiliary power.  
The automatic idle system  
functions normally when welding.  
Weld and auxiliary power is  
normal when the idle switch is in  
the “High Idle” position. The  
engine starts, runs, and shuts  
down normally.  
The load applied to the auxiliary  
receptacles may be too low. A  
load of 100 Watts minimum is  
required for the idle system to  
operate reliably.  
The Toroidal Current  
Transformer or the wiring  
connecting it to the idler/engine  
protection PC board may be  
faulty. Check the resistance of  
the toroidal current transformer.  
The resistance should measure  
10 to 14 Ohms.  
Check that any power cords are  
in good condition 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.  
The Idler/Engine Protection PC  
board may be faulty.  
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 placed in the “High”  
position. The current drawn by  
many of these devices, when  
testing the power, is too low to  
reliably activate the automatic  
idle system.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,  
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.  
Call 1-888-935-3877.  
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-20  
F-20  
NOTES  
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-21  
F-21  
TROUBLESHOOTING AND REPAIR  
ENGINE RPM ADJUSTMENT TEST  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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 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 pencil or marker  
SAE-400 SEVERE DUTY  
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F-22  
F-22  
TROUBLESHOOTING AND REPAIR  
ENGINE RPM ADJUSTMENT TEST (continued)  
FIGURE F.1 – ENGINE COMPONENTS (CODE 10856)  
Spring  
Idler Rod  
Idler  
Solenoid  
Speed  
Control  
Lever  
Ball  
Joint  
Fan Blades  
Lock  
Nut  
Pulley  
Possible Strobe-Tach  
Mark Points  
TEST PROCEDURE  
2. Connect the strobe-tach according to the manufac-  
turer’s instructions.  
1. Turn the engine off  
2. Open the left side door, on the engine end of the  
machine.  
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  
operating temperature and the RPM to stabilize.  
WARNING: Secure the door in the open position using  
the door restraint system. If the machine  
does not have a door restraint system,  
remove the door or securely restrain it to  
prevent it from falling closed.  
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.  
4. Direct the strobe-tach light on the highly visible  
mark that had been applied earlier and synchronize  
the light with the rotating mark. See the strobe-tach  
manufacturer’s instructions.  
3. Check that the linkage attaching the solenoid to the  
engine speed control lever is properly aligned and  
in good condition. It is more important that the sole-  
noid linkage be more precisely aligned when in the  
high speed (de-energized position). See Figures  
F.1 and F.2.  
Strobe-Tach Method:  
1. Place a highly visible mark on the engine crankshaft  
pulley, or another rotating component connected to  
the engine crankshaft. See Figure F.1.  
SAE-400 SEVERE DUTY  
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F-23  
F-23  
TROUBLESHOOTING AND REPAIR  
ENGINE RPM ADJUSTMENT TEST (continued)  
FIGURE F.2 – ENGINE COMPONENTS (CODE 11199 & 114080)  
SOLENOID  
BRACKET  
BALL  
JOINT  
LOCK NUT  
IDLER  
ROD  
Strobe-Tach Method (continued)  
2. Start 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.  
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 solenoid to energize, and the  
engine RPM to drop and stabilize at the low idle  
RPM.  
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  
7. Synchronize the strobe-tach to read the low idle  
RPM.  
8. The tach should read between 1000 and 1150  
RPM.  
The frequency should read between 59.3 and 60.3 Hz.  
Move the idle switch to the “AUTO IDLE” position and  
wait for the idle solenoid to energize, and the engine  
RPM to drop and stabilize at the low idle RPM.  
9. If either of the readings is incorrect, proceed to the  
“ENGINE RPM ADJUSTMENT PROCEDURE” later  
in this section.  
The frequency should read between 33.3 and 38.3Hz.  
Frequency counter method:  
If either of the readings is incorrect, proceed to the  
“ENGINE RPM ADJUSTMENT PROCEDURE” later in  
this section.  
NOTE: A dedicated frequency counter can be used for  
this test, but many high quality digital multime-  
ters also have this function, and can be easily  
utilized. See the manufacturer’s instructions  
for your frequency counter or multimeter.  
NOTE: For the SAE-400 Severe Duty, and any other  
Lincoln Electric 1800 RPM (4 Pole) machine,  
that has 60 Hz AC auxiliary power; the engine  
RPM can be determined by multiplying the fre-  
quency of the auxiliary power output, in Hz. By  
30. (Example: 60 Hz. * 30 = 1800 RPM)  
1. Set your frequency counter per the meter manufac-  
turer’s instructions, and plug the probes into one of  
the 120VAC auxiliary receptacles.  
SAE-400 SEVERE DUTY  
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F-24  
F-24  
TROUBLESHOOTING AND REPAIR  
ENGINE RPM ADJUSTMENT TEST (continued)  
ENGINE RPM ADJUSTMENT PROCEDURE  
High Idle Adjustment:  
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.  
IMPORTANT: The high idle RPM is set by the engine  
manufacturer, and should not be  
changed. If the high idle RPM is not  
within the specified range, the engine  
should be serviced by a qualified engine  
technician.  
5. Recheck the low idle RPM and adjust as needed;  
when the low idle RPM is correct, hold the idle rod in  
position and tighten the lock nut.  
Low idle adjustment:  
Code 10856 only:  
1. Hold the ball joint housing with a wrench and loosen  
the lock nut. Snap the ball joint housing off of the  
ball, (some prying may be required) Rotate the ball  
joint housing, lengthening or shortening the idle  
rod/ball joint assembly as required.  
6. Check that the idle solenoid linkage moves freely  
and does not bind. When the solenoid is energized,  
the plunger must fully seat against the stop inside  
the solenoid coil assembly.  
7. After the lock nut has been tightened, re-check the  
idle RPM.  
2. Snap the ball joint housing back on the ball and re-  
check the RPM. Repeat this adjustment procedure  
as needed. When the idle RPM is correct, hold the  
ball joint housing with a wrench and tighten the lock  
nut.  
8. If testing and service is complete, disconnect any  
test equipment and close the doors.  
3. Check that the idle solenoid linkage moves freely  
and does not bind. When the solenoid is energized,  
the plunger must fully seat against the stop inside  
the solenoid coil assembly.  
SAE-400 SEVERE DUTY  
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F-25  
F-25  
TROUBLESHOOTING AND REPAIR  
BRUSH AND SLIP RING SERVICE PROCEDURE  
(Exciter / Auxiliary Power Alternator)  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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 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)  
SAE-400 SEVERE DUTY  
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F-26  
F-26  
TROUBLESHOOTING AND REPAIR  
BRUSH AND SLIP RING SERVICE PROCEDURE  
(Exciter / Auxiliary Power Alternator) (continued)  
FIGURE F.3 – EXCITER COVER SCREW LOCATIONS  
FIVE SCREWS  
(TWO ON OTHER SIDE)  
EXCITER COVER  
PROCEDURE  
•
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.)  
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 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.  
(Generally, the brushes should be replaced if either  
brush has less than 1/4” remaining before it reach-  
es the end of its travel.)  
4. If the slip rings are very dark in color, display evi-  
dence of excessive arcing, or have worn prema-  
turely, these may be signs of a grounded or shorted  
rotor. Perform the Exciter Rotor Resistance and  
Ground Test.  
2. Remove the covers from the exciter / auxiliary  
power alternator by removing the screws securing  
it. See Figure F.3.  
3. Examine brushes, slip rings, and brush holder.  
•
Brushes should be clean and free from oil or  
grease.  
•
The brushes should be of sufficient length and  
have adequate spring tension.  
SAE-400 SEVERE DUTY  
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F-27  
F-27  
TROUBLESHOOTING AND REPAIR  
BRUSH AND SLIP RING SERVICE PROCEDURE  
(Exciter / Auxiliary Power Alternator) (continued)  
FIGURE F.4 – BRUSH LOCATIONS  
BRUSHES  
PROCEDURE (continued  
Seating brushes:  
5. Check for evidence of sticking brushes. Sticking  
brushes will normally result in the slip rings being  
pitted and discolored from excessive arcing.  
Another sign of sticking brushes is instability or loss  
of both weld and auxiliary output, but the machine  
may begin to work properly, for a short time, after  
being jarred or moved.  
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 around the circumference  
of the slip rings in the direction of rotor rotation only.  
Repeat this procedure until the surface of each brush  
is in full contact with its matching slip ring.  
6. If there is any evidence that the brushes may have  
been sticking in the brush holders, a new brush  
holder and brush assembly should be installed.  
Use low pressure compressed air to thoroughly blow  
the carbon, commutator stone, and sandpaper dust  
from the machine before operating.  
Cleaning slip rings:  
In the event that the slip rings have become dirty, dis-  
colored or mildly pitted, it will be necessary to clean  
them, using very fine (500 or 600 grit) emery cloth, or a  
220 or 320 grit commutator stone.  
Securely connect the leads to the brush terminals (see  
wiring Diagram) and replace the alternator cover if test-  
ing and service is complete.  
CAUTION: Commutator stones should only be used by  
experienced technicians who have the  
knowledge and equipment necessary to  
use them safely.  
SAE-400 SEVERE DUTY  
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F-28  
F-28  
NOTES  
SAE-400 SEVERE DUTY  
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F-29  
F-29  
TROUBLESHOOTING AND REPAIR  
EXCITER ROTOR VOLTAGE TEST  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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  
SAE-400 SEVERE DUTY  
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F-30  
F-30  
TROUBLESHOOTING AND REPAIR  
EXCITER ROTOR VOLTAGE TEST(continued)  
FIGURE F.6 – EXCITER COVER SCREW LOCATIONS  
FIVE SCREWS  
(TWO ON OTHER SIDE)  
EXCITER COVER  
PROCEDURE  
1. Turn engine off.  
3. Open either, or both of the doors on the control  
panel end of the SAE-400 machine.  
2. Make sure that the battery is fully charged and in  
good condition, and the battery connections are  
clean and tight.  
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.  
The Engine and generator should be at normal operat-  
ing temperature for this test. If the machine is cold, the  
voltage readings may be slightly higher than specified.  
4. Remove the covers from the exciter/auxiliary power  
alternator by removing the screws securing it. See  
Figure F.6.  
SAE-400 SEVERE DUTY  
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F-31  
F-31  
TROUBLESHOOTING AND REPAIR  
EXCITER ROTOR VOLTAGE TEST (continued)  
FIGURE F.7 – EXCITER ROTOR VOLTAGE TEST  
BRUSH HOLDER ASSEMBLY  
VOLTMETER LEADS  
BRUSHES  
POSITIVE  
SLIP RING  
NEGATIVE  
SLIP RING  
PROCEDURE (continued)  
If this voltage reading is correct, start the engine and  
continue the testing.  
5. Connect the volt meter probes to the brush termi-  
nals. See the wiring diagram and Figure F.7  
If this voltage is not within these limits, perform the  
Flashing Voltage Tests.  
NOTE: On this machine, and all other Lincoln Electric  
DC generator machines, the black exciter lead  
is positive, and the red lead is negative.  
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 engine protection system will  
need to be reset by switching the run/stop  
switch off, then on again.  
6. Set the RUN/STOP switch to “RUN” and the IDLE  
switch to “HIGH”. Do not start the engine at this  
time.  
7. 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. (Check this voltage)  
8. Start the engine and allow the RPM to stabilize for  
about 15 to 30 seconds.  
The meter should read 124 to 132 VDC*.  
(continued on following page)  
SAE-400 SEVERE DUTY  
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F-32  
F-32  
TROUBLESHOOTING AND REPAIR  
EXCITER ROTOR VOLTAGE TEST (continued)  
PROCEDURE (continued)  
11. Check the wiring and terminals connecting the D1  
bridge rectifier to the Exciter stator winding. See  
the wiring diagram.  
9. Set the RUN/STOP switch to “STOP”  
If the meter reading is normal, this test is complete.  
If the voltage measures zero or very near zero, the  
rotor may be shorting or grounding while spinning.  
Perform the Exciter Rotor Resistance and Ground  
Test.  
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.  
If voltage is higher than specified, the engine RPM may  
be too high, or there may be voltage intrusion from one  
of the higher voltage stator windings to the stator  
exciter winding.  
Perform the Engine RPM  
Be sure that there are no loads of any kind across any  
of the stator windings. The exciter winding should be  
the only stator winding connected at this time.  
Examine stator wiring for damage, pinched leads,  
chafed insulation, etc. If necessary, disconnect and  
insulate the stator output leads as close to the stator  
winding as possible. If any leads were disconnected,  
secure them so they cannot be damaged by moving  
parts. See wiring diagram.  
Adjustment Test, and the Exciter Stator Short  
Circuit and Ground Test.  
If the voltage is lower than 124, but higher than 14, the  
engine RPM may be too low, or there may be problems  
in the windings or other exciter circuit components or  
connections. Perform the Engine RPM Adjustment  
Test, and then perform the testing described below,  
under the heading “If the voltage measures about 2 to  
4 VDC”  
13. Re-start the machine and measure the rotor volt-  
age.  
If the meter reading indicates battery voltage, about 12  
to 14 VDC, The rotor may be opening while spinning,  
or the brushes may be faulty or not making proper con-  
tact with the slip rings while the rotor is spinning.  
Perform the Rotor Resistance Test, and the Brush  
and Slip Ring Service Procedure.  
If the rotor voltage continues to read significantly lower  
than 124VDC, the Stator is probably defective and  
should be replaced.  
NOTE: The field bridge rectifier may appear to func-  
tion normally when tested independently, but  
may malfunction when placed under the stress  
of normal operation. For this reason, it is rec-  
ommended that the bridge rectifier be replaced  
with a known good component before replac-  
ing the stator.  
If the voltage measures about 2 to 4 VDC, the genera-  
tor is not building-up to normal output even though the  
flashing circuit appears to be functioning normally. This  
condition could be caused by one of several failed  
components or connections. Continue with the follow-  
ing tests.  
* Voltages shown in this document are for a machine  
operating at normal temperature. Voltage readings  
may be slightly higher if the machine is cold.  
10. Check the D1 field bridge rectifier.  
SAE-400 SEVERE DUTY  
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F-33  
F-33  
TROUBLESHOOTING AND REPAIR  
EXCITER ROTOR RESISTANCE AND GROUND TEST  
(Exciter / Auxiliary Power Alternator)  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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 / 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  
SAE-400 SEVERE DUTY  
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F-34  
F-34  
TROUBLESHOOTING AND REPAIR  
EXCITER ROTOR RESISTANCE AND GROUND TEST  
(Exciter / Auxiliary Power Alternator) (continued)  
FIGURE F.8 – EXCITER COVER SCREW LOCATIONS  
FIVE SCREWS  
(TWO ON OTHER SIDE)  
EXCITER COVER  
PROCEDURE  
“Static” Tests:  
4. Locate and label the leads connected to the rotor  
brush holder assembly. Remove the leads.to elec-  
trically isolate the rotor windings.  
1. Turn the engine off.  
2. 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.  
3. Remove the cover from the exciter / auxiliary power  
alternator by removing the screws securing it. See  
Figure F.8.  
SAE-400 SEVERE DUTY  
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F-35  
F-35  
TROUBLESHOOTING AND REPAIR  
EXCITER ROTOR RESISTANCE AND GROUND TEST  
(Exciter / Auxiliary Power Alternator) (continued)  
FIGURE F.9 – SLIP RING LOCATIONS  
BRUSHES  
BRUSH HOLDER ASSEMBLY  
OHMMETER LEADS  
POSITIVE  
SLIP RING  
NEGATIVE  
SLIP RING  
PROCEDURE (continued)  
5. Using the ohmmeter, check the rotor winding resis-  
tance across the slip rings. Normal resistance is  
approximately 41.5* ohms, at 77°F. (25° C.) See  
Figure F.9.  
6. Measure the resistance to ground. 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.  
SAE-400 SEVERE DUTY  
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F-36  
F-36  
TROUBLESHOOTING AND REPAIR  
EXCITER ROTOR RESISTANCE AND GROUND TEST  
(Exciter / Auxiliary Power Alternator) (continued)  
FIGURE F.10 – SLIP RING LOCATIONS  
BRUSH HOLDER ASSEMBLY  
VOLTMETER LEADS  
BRUSHES  
POSITIVE  
SLIP RING  
NEGATIVE  
SLIP RING  
PROCEDURE (continued)  
“Dynamic” Tests:  
(Also referred to as flying resistance test)  
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).  
This test checks for faults in the rotor winding, while  
these windings are being stressed by the mechanical  
forces encountered during normal operation.  
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). The resistance should be very high, at  
least 500,000 (500k) ohms.  
NOTE: This test is best performed with a good quality  
analog type ohmmeter. Many digital meters will  
not provide stable or accurate resistance read-  
ings while the rotor is spinning.  
5. If the resistance readings differ significantly from the  
values indicated, re-check the brushes and the  
brush spring tension. If the brushes and slip rings  
are good, replace the rotor.  
This test requires that the brushes and slip rings are  
clean, in good condition, and are properly seated.  
Perform the Brush and Slip Ring Service Procedure.  
6. Securely connect the leads to the brush terminals  
(see wiring Diagram) and replace the alternator  
covers if testing and service is complete.  
1. Insulate the lead wires that had been disconnected  
from the brushes during the static rotor resistance  
test. Position and secure them so they cannot  
become damaged by the spinning rotor.  
*NOTE: The resistance of the copper windings will  
change with temperature. Higher tempera-  
tures will produce higher resistance, and lower  
temperatures will produce lower resistance.  
It is recommended that the ohmmeter leads be secure-  
ly attached to the brush terminals, using clips or termi-  
nals BEFORE starting the engine. See Figure F.10.  
SAE-400 SEVERE DUTY  
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F-37  
F-37  
TROUBLESHOOTING AND REPAIR  
FLASHING VOLTAGE TEST  
(Engine not running)  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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  
SAE-400 SEVERE DUTY  
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F-38  
F-38  
TROUBLESHOOTING AND REPAIR  
FLASHING VOLTAGE TEST  
(Engine not running) (continued)  
FIGURE F.12 – FLASHING VOLTAGE TEST  
FIGURE F.11 – EXCITER COVER SCREW  
LOCATIONS  
FIVE SCREWS  
BRUSH HOLDER ASSEMBLY  
(TWO ON OTHER SIDE)  
VOLTMETER LEADS  
EXCITER COVER  
BRUSHES  
POSITIVE  
SLIP RING  
NEGATIVE  
SLIP RING  
PROCEDURE  
4. Connect the volt meter probes to the brush termi-  
nals. See the wiring diagram and Figure F.12.  
1. Open either, or both of the doors on the control  
panel end of the SAE-400 machine.  
5. Set the RUN/STOP switch to “RUN”. Do not start  
the engine at this time.  
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.  
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.  
2. Remove the covers from the exciter/auxiliary power  
alternator by removing the screws. See Figure F.11.  
NOTE: If the flashing voltage reading is not taken with-  
in 30 seconds, (60 seconds with some models)  
after moving the run/stop switch to the run posi-  
tion, move the run/stop to “stop” then back to  
“run”. This resets the Idler/engine protection  
PC board.  
3. Make sure that the battery is fully charged and in  
good condition, and the battery connections are  
clean and tight.  
SAE-400 SEVERE DUTY  
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F-39  
F-39  
TROUBLESHOOTING AND REPAIR  
FLASHING VOLTAGE TEST  
(Engine not running) (continued)  
FIGURE F.13 – IDLER/ENGINE PROTECTION PC BOARD CODES 10856  
J1-1  
J1-5, CHASSIS GROUND  
(+) BATTERY VOLTAGE  
J1-10, FLASHING AND HOUR METER OUTPUT  
PROCEDURE (continued)  
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 with the tests below.  
7. If this voltage reading is correct, the test is com-  
plete.  
If the voltage is significantly higher than expected:  
8. Perform the Exciter Rotor Resistance and  
There may be an open rotor winding or faulty brushes  
or slip rings. Perform the Brush and Slip Ring  
Service Procedure, and the Exciter Rotor  
Resistance and Ground Test.  
Ground Test.  
9. Test or replace the D1 field bridge rectifier.  
If the voltage measures zero or significantly lower than  
specified (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.)  
SAE-400 SEVERE DUTY  
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F-40  
F-40  
TROUBLESHOOTING AND REPAIR  
FLASHING VOLTAGE TEST  
(Engine not running (continued)  
FIGURE F.14 – IDLER/ENGINE PROTECTION PC BOARD CODES 11199 AND 11408  
B-1 CHASSIS GROUND  
J31-10, FLASHING AND HOUR METER OUTPUT  
J31-1, (+) BATTERY VOLTAGE INPUT  
PROCEDURE (continued)  
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.  
10. Connect positive voltmeter probe to the Idler /  
Engine protection PC board J1 pin 10 for Code  
10856, (J31 pin 10 for codes 11199 and 11408).  
Connect the negative probe to a good chassis  
ground connection or the negative battery termi-  
nal.  
If battery voltage is present at J1 pin 1for code 10856,  
(J31-pin 1 for codes 11199 and 11408), check that the  
Idler/Engine protection PC board is properly grounded.  
Lead wire #5A connects J1 pin 5 to chassis ground for  
code 10856. Wire GND-A connects terminal B1 to  
chassis ground on codes 11199 and 11408.  
11. Move the run/stop switch to “run” and read the volt-  
age within 30 seconds of switching to “run”.  
If battery voltage is detected:  
Test the flashing diode and resistor assembly, and the  
two diode and leads connecting the negative side of  
the D1 bridge rectifier to chassis ground. Also check all  
of the wiring and connections between the Idle / Engine  
Protection PC board, and the positive brush terminal.  
See the wiring diagram.  
12. If the idler/engine protection PC board is getting  
power, and has a good chassis ground connec-  
tion, but is not producing flashing voltage during  
the first 30 seconds after power-up. Replace the  
Idler/Engine Protection PC board  
If battery voltage is not present, move the positive  
probe to J1, pin 1 for code 10856, (J31, pin 1 for Codes  
11199 and 11408), and check the voltage.  
When testing is complete, replace all covers and close  
the doors.  
SAE-400 SEVERE DUTY  
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F-41  
F-41  
TROUBLESHOOTING AND REPAIR  
EXCITER STATOR SHORT CIRCUIT & GROUND TEST  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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 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 voltage fails to build-up to normal levels, or is too high in one  
or more of the windings.  
MATERIALS NEEDED  
Miscellaneous hand tools  
Ohm Meter  
SAE-400 SEVERE DUTY  
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F-42  
F-42  
TROUBLESHOOTING AND REPAIR  
EXCITER STATOR SHORT CIRCUIT & GROUND TEST (continued)  
PROCEDURE  
5. Using an ohmmeter; check the resistance between  
the following points. Resistance should read very  
high, 500,000 (500k) ohms minimum.  
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 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.  
•
•
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.  
2. Make sure that nothing is plugged into the auxiliary  
receptacles.  
If any of these readings are less than 500,000 (500k)  
ohms, be certain that the windings are completely dry  
and check for grounded components or wiring that  
remain connected to the stator, such as circuit break-  
ers, receptacles, etc. See wiring diagram. If neces-  
sary, disconnect and isolate the stator leads as close to  
the stator winding as possible.  
3. Disconnect and isolate the ground lead connected  
to the neutral side of the 115 VAC auxiliary recepta-  
cle. See the wiring diagram.  
4. Disconnect and isolate the exciter winding leads.  
(Leads 4 and 5 for code 10856, leads 203A and  
602C for codes 11199 and 11408.) See the wiring  
diagram.  
If the low resistance to ground, or between individual  
stator windings is determined to be within the stator,  
the stator is defective and should be replaced.  
SAE-400 SEVERE DUTY  
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F-43  
F-43  
TROUBLESHOOTING AND REPAIR  
WELDING GENERATOR BRUSH AND COMMUTATOR INSPECTION AND  
SERVICE  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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 provides guidelines for 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 hazardous if done without proper  
training, tools and protective equipment. Consult the commutator stone  
manufacturer’s instructions before attempting this procedure.  
SAE-400 SEVERE DUTY  
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F-44  
F-44  
TROUBLESHOOTING AND REPAIR  
WELDING GENERATOR BRUSH AND COMMUTATOR INSPECTION AND  
SERVICE (continued)  
FIGURE F.15 – GENERATOR COVER SCREW LOCATIONS  
GENERATOR COVER  
FOUR SCREWS TOTAL  
PROCEDURE  
1. Shut off the engine.  
3. Disconnect the negative battery cable.  
4. Remove the sheet metal covers protecting the  
welder generator brushes. See Figure F.15.  
2. 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.  
SAE-400 SEVERE DUTY  
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F-45  
F-45  
TROUBLESHOOTING AND REPAIR  
WELDING GENERATOR BRUSH AND COMMUTATOR INSPECTION AND  
SERVICE (continued)  
FIGURE F.16 – GENERATOR COMPONENTS  
SPRINGS  
BRUSH HOLDER PLATE  
BRUSH HOLDER  
INSULATORS  
MOUNTING SCREW  
DRILL MARK  
ROCKER  
COMMUTATOR  
ARMATURE  
BRUSHES  
BRUSH RETAINER  
PROCEDURE  
•
Perform the Weld Circuit Ground and Short  
5. Examine the Commutator.  
Circuit Test.  
Normal appearance:  
The commutator should appear smooth, and have an  
even brown color where the brushes ride.  
•
•
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 stone or sand paper.  
Blackened Commutator:  
A commutator that appears to have an even black color  
all around may indicate a grounded armature, shorted  
weld circuit, a serious overload condition, or out-of-  
adjustment rocker. It could also indicate the use of  
poor quality brushes, or brushes that have been conta-  
minated with oil or some other foreign substance.  
If brush quality or contamination is not suspected,  
clean the commutator by lightly stoning the sur-  
face.  
CAUTION: Stoning the commutator involves pressing  
an abrasive stone against a spinning com-  
mutator. This procedure can be haz-  
ardous if done without proper training,  
tools and protective equipment. Consult  
the commutator stone manufacturer’s  
instructions before attempting this proce-  
dure.  
•
Check the rocker position. Be certain that it is  
aligned with or very close to the factory drill mark.  
See Figure 16. IMPORTANT: If 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.  
SAE-400 SEVERE DUTY  
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F-46  
F-46  
TROUBLESHOOTING AND REPAIR  
WELDING GENERATOR BRUSH AND COMMUTATOR INSPECTION AND  
SERVICE (continued)  
•
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.  
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 worn  
brushes. The brush spring tension may have been too  
low, or the brushes may have been sticking in the hold-  
ers. An out-of-adjustment rocker or a serious overload  
may also cause this condition.  
Examine the brushes:  
The brushes and springs should all be in place and not  
be excessively worn. Brushes should be replaced if  
they are worn to within ¼” of the pigtail lead.  
•
Examine the inside of the brush covers and other  
parts that are close to the commutator. If there is  
a significant amount of solder and debris that has  
been thrown from the commutator, the armature  
will need to be replaced and the stator coils must  
be carefully examined and tested for damage.  
The pigtail lead of each brush should be positioned so  
it allows free movement of the brush while it wears.  
The brushes should be seated so that the face of each  
brush makes 95% minimum contact with the commuta-  
tor. Lightly stone the commutator to seat the brushes.  
See caution note on commutator stone usage.  
•
•
Perform the Weld Circuit Ground and Short  
Circuit Test.  
If the brushes are worn out, replace them and re-  
surface or clean the commutator as needed. If re-  
cutting is required, the minimum diameter of the  
commutator is 6.895 in. If the brush springs  
appear weak, discolored or damaged in any way,  
replace them as well. The brush holder plates and  
retainers should be clean, smooth, and undam-  
aged so the brushes can move freely as they wear.  
Examine the brush holders:  
The brush holder insulators must be clean and in good  
condition and all of the hardware must be in place. See  
Figure F.16. Replace any insulators that are cracked  
or damaged in any way.  
•
Check the rocker position. Be certain that it is  
aligned with or very close to the factory drill mark.  
See Figure F.16. IMPORTANT: If the rocker posi-  
tion requires adjustment, do not over tighten the  
rocker clamping screw. This screw should be tight-  
ened to a torque of 70 to 75 Inch-Lbs. Over tight-  
ening can destroy the rocker.  
When installing the brush holders, they should be rotat-  
ed toward the brush retainer (clockwise rotation when  
facing the brush holder mounting screw.) until they  
stop. The edge of the brush holder plate should be par-  
allel with the surface of the commutator and positioned  
.030 to .090 from the surface of the commutator. The  
brush holder mounting screw should be tightened to a  
torque of 24 to 28 Ft Lbs.  
Uneven Commutator appearance:  
If the commutator appears to have some normal col-  
ored bars and some blackened bars, the armature may  
be shorted.  
The brush holder plate and retainer assembly must be  
clean and smooth; nothing should prevent free move-  
ment of the brushes. All electrical connections to the  
brush holders must be clean, and tight. The recom-  
mended torque for 5/16-18 brush holder connection  
screws is 8 Ft.-Lbs.  
•
If excessive sparking is observed and/or the weld  
output is abnormal, the armature should be  
replaced.  
SAE-400 SEVERE DUTY  
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F-47  
F-47  
TROUBLESHOOTING AND REPAIR  
WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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 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 this test is done.  
.
MATERIALS NEEDED  
Miscellaneous hand tools  
Ohm meter or Multimeter  
Wiring diagram  
SAE-400 SEVERE DUTY  
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F-48  
F-48  
TROUBLESHOOTING AND REPAIR  
WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST (continued)  
PROCEDURE  
1. Turn the engine off.  
If the commutator has low resistance to chassis  
ground, the armature is defective.  
Weld circuit ground test:  
7. If the resistance measured at the “WORK” terminal  
is low, carefully examine the interpole coils, and the  
heavy leads, and the brush holders 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.  
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 ground  
connection.  
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 dirty weld output “ELECTRODE” terminal.  
If necessary, disconnect the output control unit and  
test it separately. See the Output Control Unit  
(Variable Reactor) Inspection and Service  
Procedure.  
3. The resistance measurement should be very high  
500,000 (500k) Ohms minimum.  
If the resistance is lower than 500k Ohms:  
4. Move the output control away from the minimum  
position and recheck the resistance. If the resis-  
tance is now 500k Ohms or greater; check for a  
damaged or missing insulator bushing at the output  
control unit.  
9. Test for a short circuit condition between the elec-  
trode and work circuits.  
10. With the brushes still isolated as described above,  
check the resistance between the two weld termi-  
nals. The resistance should be very high, 500,000  
(500k) Ohms minimum.  
5. If the resistance is still less than 500k Ohms,  
Remove the welding generator brushes, or pull  
them away from the commutator and isolate them  
so they cannot come in contact with anything  
except the brush holder where they are attached.  
11. If the resistance measurement is too low, check  
the heavy weld current carrying leads and connec-  
tions for damaged insulation or dirt buildup  
between the electrode (Series Coils) and work  
(Interople Coils) circuits. If the low resistance point  
is between the stator coils, the coils will require  
replacement or repair.  
6. Check the resistance between chassis ground and  
each output terminal, and between chassis ground  
and the commutator.  
SAE-400 SEVERE DUTY  
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F-49  
F-49  
TROUBLESHOOTING AND REPAIR  
SHUNT FIELD COIL RESISTANCE AND GROUND TEST  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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 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  
Wiring diagram  
SAE-400 SEVERE DUTY  
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F-50  
F-50  
TROUBLESHOOTING AND REPAIR  
SHUNT FIELD COIL RESISTANCE AND GROUND TEST (continued)  
PROCEDURE  
1. Turn the engine off.  
Shunt Coil Ground Test:  
2. Open both of the doors on the control panel end of  
the SAE-400 machine. The roof may also need to  
be removed on some models.  
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 measure the resistance between either  
of the resistor terminals and a good clean chassis  
ground. The resistance should be very high,  
500,000 (500k) Ohms minimum.  
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.  
Shunt Coil Resistance Test:  
• If the resistance is too low, disconnect the shunt  
coil leads from the resistor and position them so  
they cannot make electrical contact with any-  
thing. See the wiring diagram. Test the resis-  
tance between either of the shunt coil lead wires  
and a good, clean chassis ground.  
3. Place the polarity switch in the “OFF” position.  
Locate the 500 Ohm/50 Watt resistor located on the  
back of the control panel, just below the 115 VAC  
duplex receptacle. Leave all of the leads connect-  
ed to the resister, and measure the resistance  
across  
it.  
The resistance should measure approximately  
36.5* ohms at 77°F. (25° C.)  
• If the resistance is still lower than 500,000 (500k)  
Ohms, check the shunt coil leads between the  
test points and the coils. Also check the lead  
connecting the two shunt coils together inside of  
the generator. Look for pinched wires and dam-  
aged insulation. If the low resistance is deter-  
mined to be between chassis ground and one of  
the shunt coils, replace the coil set.  
If the resistance reading is correct, proceed to the  
Shunt coil ground test.  
• If the resistance reading is slightly high, about 40*  
Ohms, The 500 Ohm resistor may be open.  
• If the resistance is significantly higher than 40*  
Ohms, check the wiring between the test points  
and the shunt coils. Check the lead connecting  
the two shunt coils together inside the generator  
frame. See the wiring diagram and the internal  
generator diagram. If these wires and connec-  
tions are undamaged, one of the coils is likely  
open. Replace the shunt field coil set.  
• If the coil set tests normal when disconnected,  
check the resistor and polarity switch for low  
resistance to chassis ground. Repair or replace  
these parts as needed.  
• If the resistance is significantly lower than 36.5*  
Ohms at 77°F. (25° C.), check the wiring between  
the test points and the coils for damaged insula-  
tion, pinched wires, etc. If the wires and insula-  
tion are in good condition, disconnect at least one  
of the shunt coil wires from the resistor and test  
the resistance of just the shunt coil set. See the  
wiring 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.  
5. Reconnect the wires and replace any covers that  
have been removed.  
*NOTE: The resistance of the copper windings will  
change with temperature. Higher tempera-  
tures will produce slightly higher resistance,  
and lower temperatures will produce slightly  
lower resistance.  
SAE-400 SEVERE DUTY  
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F-51  
F-51  
TROUBLESHOOTING AND REPAIR  
SHUNT FIELD CIRCUIT VOLTAGE TEST  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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 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 meter or Multimeter  
Wiring diagram  
SAE-400 SEVERE DUTY  
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F-52  
F-52  
TROUBLESHOOTING AND REPAIR  
SHUNT FIELD CIRCUIT VOLTAGE TEST (continued)  
PROCEDURE  
If the measured voltage is normal, but there is still no  
usable output from the welding generator, perform the  
Shunt Field Coil Resistance and Ground Test.  
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 be  
removed on some models.  
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.  
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.  
If about 140 VDC is present at the D2 bridge rectifier,  
check the wiring between the rectifier, the polarity  
switch and the 500 Ohm resistor. If the wiring and con-  
nections are all good, the polarity switch may be faulty.  
If the voltage is not present at the DC terminals of the  
D2 rectifier, check for approximately 125 VAC at the AC  
terminals of the D2 rectifier. If this AC voltage is pre-  
sent, replace the D2 rectifier.  
3. Place the rheostat in the maximum position and ver-  
ify that the polarity switch is either the positive or  
negative position. It must not be in the neutral posi-  
tion.  
If AC voltage is not present, check the remote/local  
switch, the P8 harness plug and receptacle. Check all  
the wiring and connections between the D2 and the D1  
rectifiers. See the wiring diagram.  
4. Place the remote/local switch in the local position.  
5. Place the idle switch in the high idle position, start  
the engine and allow it to stabilize at high idle RPM.  
7. Check the Rheostat.  
6. Locate the 500 Ohm/50 Watt resistor located on the  
back of the control panel, just below the 115 VAC  
duplex receptacle, and measure the voltage across  
it. The voltage should measure about 140 VDC.  
SAE-400 SEVERE DUTY  
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F-53  
F-53  
TROUBLESHOOTING AND REPAIR  
DEAD SHORT, 1ST STEP, AND OPEN REACTOR TESTS  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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 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 short length of heavy cable to short the output, or load bank with shorting contactor  
SAE-400 SEVERE DUTY  
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F-54  
F-54  
TROUBLESHOOTING AND REPAIR  
DEAD SHORT, 1ST STEP, AND OPEN REACTOR TESTS (continued)  
FIGURE F.17 – OUTPUT CONTROL UNIT  
ROTOR  
WINDING  
MOVABLE CONTACTS  
Min. (open) Position  
FIRST STEP  
CONTACT  
CONTACT SPRINGS  
POSITION  
INSULATED  
FILLER  
PROCEDURE  
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*.  
1. If possible, bring the machine to normal tempera-  
ture by connecting a load bank and operating the  
machine at 100% output (400 amps @ 36 volts) for  
about 30 minutes.  
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  
contacts themselves, may be making contact with the  
output control winding. Perform the Output Control  
Unit Inspection and Service Procedure.  
2. Remove the load; turn the Job Selector Rheostat to  
MAXIMUM, and the Current Control to MINIMUM  
(Contacts on the insulated steel filler or “Open  
Reactor”).  
3. Short the output terminals and check that the  
machine output is 135 to 165 Amps, at 0.2 to 4 Volts  
DC*.  
No change in the output as the output control is slowly  
increased to the first step would indicate an open  
Output Control Unit, or an open in the cables connect-  
ing to it. See the wiring diagram, and perform the  
Output Control Unit Inspection and Service  
Procedure.  
If there is no output at the Min. setting of the output  
control, there is probably an open circuit in the Series  
coils or the conductors connecting them. See the  
Internal generator diagram, and the wiring diagram  
.
A high output when the reactor is set to Min. would indi-  
cate a possible short in the series coils. See the inter-  
nal generator diagram.  
* These values will be accurate if machine is operating  
at normal temperature. If the machine is cold, the val-  
ues will be higher.  
SAE-400 SEVERE DUTY  
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F-55  
F-55  
TROUBLESHOOTING AND REPAIR  
ROCKER ADJUSTMENT PROCEDURE  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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  
The rocker is the part of the welding generator that supports and positions the 4 sets of  
brushes. Its position can be adjusted to fine tune the weld output and influence the weld  
characteristics.  
IMPORTANT: The rocker is set at the factory for the best overall 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 desired application.  
CAUTION: Improper rocker adjustment can result in poor performance, reduced brush  
life and damage to the welding generator. This adjustment should only be  
attempted by an experienced professional.  
MATERIALS NEEDED  
Resistive load bank, capable of absorbing at least a 500 Amp load.  
Volt meter  
Ammeter, able to read at least 500 Amps  
Miscellaneous hand tools  
Drill with 1/8” bit  
Tachometer or frequency meter.  
SAE-400 SEVERE DUTY  
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F-56  
F-56  
TROUBLESHOOTING AND REPAIR  
ROCKER ADJUSTMENT PROCEDURE (continued)  
FIGURE F.18 – ROCKER W/MARKS  
SPRINGS  
BRUSH HOLDER PLATE  
BRUSH HOLDER  
INSULATORS  
MOUNTING SCREW  
DRILL MARK  
ROCKER  
COMMUTATOR  
ARMATURE  
BRUSHES  
BRUSH RETAINER  
PROCEDURE  
The factory set point drill marks:  
1. When the rocker is set for the first time at the facto-  
ry, a 1/8” drill is used to mark the position of both the  
rocker and the exciter bracket. See Figure F.18  
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 all the other systems have  
been thoroughly checked and are func-  
tioning normally.  
If a machine is not operating within the specified limits,  
and nothing else appears to be faulty, the rocker posi-  
tion should be checked. If the drill marks are not  
aligned, the rocker and/or the exciter bracket should be  
reset to the original factory position.  
A tachometer will be required for this phase of the test.  
See the Engine RPM Adjustment Test for details  
about measuring engine RPM.  
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 ½ the diameter of  
the drill mark.  
SAE-400 SEVERE DUTY  
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F-57  
F-57  
TROUBLESHOOTING AND REPAIR  
ROCKER ADJUSTMENT PROCEDURE (continued)  
PROCEDURE (continued)  
Initial rocker placement:  
WARNING: Do not move the Current Control while  
the machine is under load.  
1. The rocker should be initially positioned so the  
center of brushes visually lines up with the  
center of the main poles. Lining up the four  
brush holder studs with the four exciter brack-  
et mounting bolts is acceptable for initial place-  
ment. The rocker should be tight against the  
shoulder of the hub and the clamping screw  
should be tightened only enough to assure the  
rocker cannot move.  
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.  
IMPORTANT: DO NOT OVER TIGHTEN. Over  
tightening the rocker clamp screw  
can destroy the rocker.  
If the engine RPM is not within specification,  
Perform the Engine RPM Adjustment Test, if the  
engine high idle RPM is normal, but the load RPM  
is significantly less than specified above, the  
engine or governor may be malfunctioning. See  
the engine troubleshooting procedures in this man-  
ual and/or have the engine serviced or repaired by  
a qualified engine technician.  
2. Check that the brush holders are properly  
installed and positioned correctly. See the  
Welding generator Brush and Commutator  
Inspection and Service Procedure.  
If the weld output voltage is lower than specified  
above, the rocker position will need to be adjusted.  
Generally, moving the rocker opposite the arma-  
ture rotation direction will increase output voltage.  
When making this adjustment, the rocker should  
only be moved in very small increments. The  
adjustment may need to be repeated several times  
to achieve the desired result.  
3. Start the engine, place the idle switch in the  
high idle position, and seat the brushes using  
a commutator stone. See the Welding gener-  
ator Brush and Commutator Inspection and  
Service Procedure.  
4. Use a load bank to apply a 100% duty cycle  
load (400 amps @ 36 volts). Look at the  
brushes while the load is applied. If excessive  
sparking is observed, adjust the rocker position  
to minimize sparking. Generally, moving the  
rocker slightly in the direction of the armature  
rotation will reduce sparking.  
9. Remove the load and check the voltage at the  
output studs (OCV). The voltage should mea-  
sure 93 to 99 Volts DC.  
After the rocker has been adjusted and the  
machine is operating normally, the rocker locking  
screw should be tightened to 70-75 Inch-Lbs.  
5. Continue running the machine under load for  
at least 30 minutes to bring the machine up to  
normal operating temperature and to fully seat  
the brushes.  
If new parts had been installed, the new rocker  
and/or exciter bracket location should be marked  
with a 1/8” drill mark. See Figure F.18.  
Check for Max output.  
6. Remove the load, set the output control and  
rheostat to maximum, re-apply the load and  
adjust the load bank to apply a 500 Amp load  
to the machine.  
SAE-400 SEVERE DUTY  
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F-58  
F-58  
NOTES  
SAE-400 SEVERE DUTY  
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F-59  
F-59  
TROUBLESHOOTING AND REPAIR  
OUTPUT CONTROL UNIT (VARIABLE REACTOR)  
INSPECTION AND SERVICE PROCEDURE  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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  
The output control unit, also known as a variable reactor, functions like a very high cur-  
rent, highly specialized rheostat. 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 called for in the dead short, first step, or open reactor tests. It should also be  
done if the weld output is low or erratic, and the auxiliary output is normal.  
MATERIALS NEEDED  
Miscellaneous Hand Tools  
400 to 600 Grit sand paper  
Ohm meter  
SAE-400 SEVERE DUTY  
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F-60  
F-60  
TROUBLESHOOTING AND REPAIR  
OUTPUT CONTROL UNIT (VARIABLE REACTOR)  
INSPECTION AND SERVICE PROCEDURE (continued)  
FIGURE F.19 – BRUSH & SPRING  
WINDING  
Output Stud  
Brush  
Assembly  
Holder  
Assembly  
Contacts &  
Springs  
PROCEDURE  
5. Disassemble the continuous control unit:  
1. Turn the engine off, open the doors on the control  
panel end of the machine and disconnect the nega-  
tive battery cable. The doors must be secured while  
disconnecting the battery cable.  
If service is necessary, remove the fuel tank and dis-  
connect the heavy cable attached to the output stud, at  
the center back on the output control.  
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.  
6. Remove the Output control handle.  
7. Remove the two screws holding the Brush holder  
stud assembly. Use caution, the shaft is under  
spring tension. The stud assembly and the rotating  
brush holder/contact assembly can now be  
removed through the back of the unit. See Figures  
F19 and F.20.  
2. Remove the roof and doors.  
3. Inspect the output control unit:  
4. Carefully examine the unit. Check for arc damage,  
missing or broken springs, burned and/or badly  
worn 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.  
SAE-400 SEVERE DUTY  
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F-61  
F-61  
TROUBLESHOOTING AND REPAIR  
OUTPUT CONTROL UNIT (VARIABLE REACTOR)  
INSPECTION AND SERVICE PROCEDURE (continued)  
FIGURE F.20 – BRUSH & SPRING  
WINDING  
INSULATED  
WEDGE  
PROCEDURE (continued)  
Servicing the continuous control unit:  
The resistance should be very high, 500,000 (500k)  
Ohms min.  
8. Clean the continuous output control unit by using  
low pressure air to remove any excess dust and dirt.  
If the unit is greasy or oily, a more thorough clean-  
ing will be required. The unit must be clean and  
completely dry before continuing.  
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 continuous output control unit, it will need to be  
replaced.  
9. Ground test the unit by testing the resistance  
between the following points:  
• Chassis ground to winding  
• Chassis ground to the insulated steel wedge (at  
the bottom of continuous output control inside  
diameter)  
Use very fine, 400 to 600 grit sand paper or a cylinder  
hone to clean away any dirt, oxidation, or minor arc pit-  
ting from the output control bore.  
• Insulated steel wedge to the winding. See Figure  
F.20.  
SAE-400 SEVERE DUTY  
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F-62  
F-62  
TROUBLESHOOTING AND REPAIR  
OUTPUT CONTROL UNIT (VARIABLE REACTOR)  
INSPECTION AND SERVICE PROCEDURE (continued)  
PROCEDURE  
The resistance should be very high, 500,000 (500k)  
Ohms min.  
Servicing the rotating brush holder and output  
stud assembly:  
If any of the contacts on the brush holder assembly are  
damaged, install all new contacts and new springs.  
Thoroughly clean and inspect the rotating brush holder  
assembly and the output stud assembly.  
13. Assemble the flat washer, spring clip, and coil  
spring to the shaft. See figure F.21  
10. Examine the insulators on both assemblies. See  
Figure F.21. Replace any that are worn, damaged  
or missing. If the shaft insulation tube requires  
replacement, position the shaft and tube per  
Figure F.22, and torque the two 5/16-18 Hex head  
screws to 8 Ft-Lbs.  
14. Apply a thin layer of grease to both the output stud  
and the inside of the brush holder that mates to the  
output stud. Grease should also be applied to the  
area around the hole where the shaft passes  
through the front panel.  
11. Disassemble the output stud assembly and check  
the insulating washers and tube. Replace them if  
they are damaged or worn and re-assemble the  
output stud assembly. See Figure F.21  
15. Insert the brush holder and output stud assembly  
through the output control unit and through the  
hole in the front panel. Be sure the output stud  
bracket is positioned correctly. The insulated stop  
should be on the left when facing the back on the  
output control unit.  
12. Check for grounded output stud and brush holder  
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  
FIGURE F.21 – INSULATOR & SPRING LOCATIONS  
Steel  
Shaft  
Coil  
Spring  
Insulator  
Tube  
Output  
Contacts  
Stud  
Springs  
Insulator  
(Short Insulator Tube Not Shown)  
Brush  
Holder  
Spring  
Clip  
Flat  
Washer  
Output  
Stud  
Bracket  
SAE-400 SEVERE DUTY  
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F-63  
F-63  
TROUBLESHOOTING AND REPAIR  
OUTPUT CONTROL UNIT (VARIABLE REACTOR)  
INSPECTION AND SERVICE PROCEDURE (continued)  
FIGURE F.22 – SHAFT & TUBE  
CHAMFERED END OF SHAFT  
AT THIS END  
7
5/8”  
4
1/4”  
PROCEDURE (continued)  
The shaft spring will need to be compressed and the  
bracket drawn close to the back of the output control  
before the screws can be started and tightened.  
Locking 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.  
SAE-400 SEVERE DUTY  
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F-64  
F-64  
NOTES  
SAE-400 SEVERE DUTY  
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F-65  
F-65  
TROUBLESHOOTING AND REPAIR  
ENGINE PROTECTION SYSTEM CIRCUIT TEST  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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 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 meter  
Wiring diagram  
SAE-400 SEVERE DUTY  
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F-66  
F-66  
TROUBLESHOOTING AND REPAIR  
ENGINE PROTECTION SYSTEM CIRCUIT TEST (continued)  
FIGURE F.23 – ENGINE ALTERNATOR CODE 10856  
#237  
GROUND  
#224  
PROCEDURE  
1. Disconnect the lead from the engine coolant tem-  
perature gage or switch.  
IMPORTANT: Before proceeding with this test, verify  
that the engine has normal oil pressure,  
is not overheated, and the alternator  
drive belt is in place and properly ten-  
sioned.  
Code 10856, temp gage, Lead wire #221  
Codes 11199 & 11408, temp switch, lead #44  
Open all of the doors on the SAE-400 machine.  
2. Disconnect the lead from the engine oil pressure  
switch.  
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.  
Code 10856, lead #223  
Codes 11199 & 11408, lead #54  
CAUTION: The following procedure will temporarily  
disable the engine protection system. Be  
absolutely certain that engine temperature  
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.  
3. Disconnect the flash/sense lead from the engine  
alternator.  
Code 10856, lead #224  
Codes 11199 & 11408, lead #59  
SAE-400 SEVERE DUTY  
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F-67  
F-67  
TROUBLESHOOTING AND REPAIR  
ENGINE PROTECTION SYSTEM CIRCUIT TEST (continued)  
FIGURE F.24 – ENGINE ALTERNATOR CODE 11199 &11408  
#59  
#51  
PROCEDURE (continued)  
4. Insulate and/or position these leads so they cannot  
touch chassis ground, any other electrical conduc-  
tor, or be damaged by any moving parts.  
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.  
5. Start the engine and allow it to run.  
10. If the engine continues to run after reconnecting  
one of the wires, repeat step #9, connecting one of  
the two remaining wires, then repeat step #9 again  
connecting the last wire. Repair or replace any  
faulty component.  
6. If the engine still shuts down, thoroughly check the  
three wires that had been disconnected in steps 1  
through 3. Be particularly aware of damaged insu-  
lation, or anything that may cause one of these  
conductors to come in contact with chassis ground.  
Be certain to reconnect all lead wires and close the  
doors when testing and service is complete.  
7. If no problems are discovered with the wiring or  
insulation, the Idler/Engine shutdown PC board is  
faulty and should be replaced.  
8. If the engine continues to run with these wires dis-  
connected, one of the engine protections switches  
is faulty or the engine alternator is faulty.  
SAE-400 SEVERE DUTY  
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F-68  
F-68  
NOTES  
SAE-400 SEVERE DUTY  
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F-69  
F-69  
TROUBLESHOOTING AND REPAIR  
ENGINE ALTERNATOR TEST  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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  
SAE-400 SEVERE DUTY  
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F-70  
F-70  
TROUBLESHOOTING AND REPAIR  
ENGINE ALTERNATOR TEST (continued)  
FIGURE F.25 – ALTERNATOR CODE 10856  
#237  
GROUND  
#224  
PROCEDURE  
• 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.  
1. Open the right side cover, on the radiator end of the  
SAE-400 machine.  
WARNING: Secure the door in the open position using  
the door restraint system. If the machine  
does not have a door restraint system,  
remove the door(s) or securely restrain  
them to prevent them from falling closed.  
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  
Volts DC during first 30 seconds of operation.  
(This time may be 60 seconds on some models.)  
2. Locate the engine alternator (See Figure F.25 &  
Figure F.26)  
3. Check voltage as follows:  
4. Run/stop switch off:  
• Chassis ground to the B+ terminal of the alterna-  
tor, (Lead #237 for code 10856) (Lead #51 for  
codes 11199 and 11408) the meter should read  
battery voltage.  
SAE-400 SEVERE DUTY  
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F-71  
F-71  
TROUBLESHOOTING AND REPAIR  
ENGINE ALTERNATOR TEST (continued)  
FIGURE F.26 – ALTERNATOR CODE 11199 & 11408  
#59  
#51  
PROCEDURE (continued)  
Engine running:  
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 replaced.  
• Chassis ground to the B+ terminal of the alterna-  
tor, (Lead #237 for code 10856) (Lead #51 for  
codes 11199 and 11408) the meter should read  
about 13.5 to 14.2 VDC.  
• Chassis ground to the alternator flash/sense  
lead, (Lead #224 for cod 10856) (Lead #59 for  
codes 11199 and 11408) the meter should read  
about 10 Volts DC.  
NOTE: A closed temperature 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.  
SAE-400 SEVERE DUTY  
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F-72  
F-72  
NOTES  
SAE-400 SEVERE DUTY  
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F-73  
F-73  
TROUBLESHOOTING AND REPAIR  
ENGINE FUEL SYSTEM VOLTAGE TESTS  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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 fuel system is getting the electrical power needed to function  
correctly.  
MATERIALS NEEDED  
Miscellaneous hand tools  
Multimeter, or a volt meter and ohm meter  
SAE-400 SEVERE DUTY  
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F-74  
F-74  
TROUBLESHOOTING AND REPAIR  
ENGINE FUEL SYSTEM VOLTAGE TESTS (continued)  
FIGURE F.27 – PC BOARD  
J1-9 (+), 11 TO 13 VOLTS  
TO FUEL SOLENOIDS  
J1-1 (+), BATTERY  
VOLTAGE INPUT TO  
PC BOARD  
J1-5 (-), CHASSIS  
GROUND  
PROCEDURE  
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 the temperature  
switch and other fuel system electrical compo-  
nents.  
1. Open the doors on 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.  
If battery voltage is present at the solenoids and the  
fuel pump (If equipped), and the starter motor is crank-  
ing the engine normally, the problem is likely in the  
engine. Engine problems should be diagnosed and  
repaired by a qualified Perkins engine technician.  
2. Check the wiring and connections on the  
Idle/Engine protection PC board, the engine fuel  
system injection pump solenoids, the fuel system  
temperature switch, (The fuel pump for Codes  
11199 & 11408), and chassis ground. Look for dirty,  
corroded, or damaged terminals, including the  
Molex terminals connecting the wiring to the PC  
board. Look for poor crimp connections and dam-  
aged wiring.  
If battery voltage is not present at the solenoids and  
fuel pump (if equipped) follow the procedures below.  
3. Make sure the batteries are in good condition, and  
are fully 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.  
SAE-400 SEVERE DUTY  
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F-75  
F-75  
TROUBLESHOOTING AND REPAIR  
ENGINE FUEL SYSTEM VOLTAGE TESTS (continued)  
FIGURE F.28 – PC BOARD  
B-1 (-) CHASSIS GROUND  
J31-9 (+) OUTPUT TO FUEL SOLENOIDS  
AND PUMP  
J31-1, (+) BATTERY VOLTAGE INPUT  
PROCEDURE  
For Code 10856:  
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.  
1. Place the run/stop switch in the “RUN” position and  
within 30 seconds, check for battery voltage  
between terminal J1-9 (+) and terminal J1-5 (-).  
See Figure #1.  
IMPORTANT: If the PC board is defective, test the  
solenoids and engine temperature  
switch as follows, before installing the  
new PC board.  
2. Check for battery voltage between terminal J1-1  
(+) and terminal J1-5 (-).  
If the correct voltage is present for both tests, check the  
wiring and connections between the PC board and fuel  
system solenoids and temperature switch. Check the  
wiring and connections between the solenoids and  
chassis ground. See the wiring diagram.  
3. Disconnect both solenoids and the engine tempera-  
ture switch, and then check the resistance across  
each solenoid. See the machine schematic for  
approximate resistance values. Check the resis-  
tance between each solenoid and chassis ground,  
and between the engine temperature switch and  
chassis ground. The resistance should be very  
high, 500,000 (500k) Ohms minimum. A qualified  
Perkins engine technician should repair or replace  
any defective components before a new PC board  
is installed.  
If no voltage is present for either test, check the  
run/stop switch and all wiring and connections between  
terminal J1-1 and the positive battery terminal. Check  
all the wiring and connections between J1-5 and the  
negative battery terminal. See wiring diagram.  
SAE-400 SEVERE DUTY  
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F-76  
F-76  
TROUBLESHOOTING AND REPAIR  
ENGINE FUEL SYSTEM VOLTAGE TESTS (continued)  
PROCEDURE  
For Codes 11199 and 11408  
1. Place the run/stop switch in the “RUN” position and  
within 30 seconds, check for 11 to 13 VDC  
between terminal J31-9 (+) and terminal B-1 (-).  
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 should be replaced.  
2. Check for battery voltage between terminal J31-1  
(+) and terminal B-1 (-).  
3. Check for positive battery voltage between the ter-  
minal where lead 212F connects to the engine tem-  
perature switch and a good chassis ground. See  
the wiring diagram.  
NOTE: The fuel solenoids, temperature switch and the  
fuel pump are part of the Perkins engine and  
should be tested and, if necessary, repaired or  
replaced by a qualified Perkins engine techni-  
cian. To help in precisely identifying a fuel sys-  
tem failure, approximate solenoid resistance  
values and current draw for the fuel pump are  
included on the machine schematic.  
If the correct voltage is present for tests #1 and #2,  
check the wiring and connections between the PC  
board, the primary solenoid, and the fuel pump. See  
wiring diagram.  
If no voltage is present for tests #1 and #2, check the  
run/stop switch and all wiring and connections between  
terminal J31-1 and the positive battery terminal. Check  
all the wiring and connections between Terminal B-1  
and the negative battery terminal. See wiring diagram.  
SAE-400 SEVERE DUTY  
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F-77  
F-77  
TROUBLESHOOTING AND REPAIR  
ALTERNATOR ROTOR REMOVAL AND REPLACEMENT  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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 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  
SAE-400 SEVERE DUTY  
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F-78  
F-78  
TROUBLESHOOTING AND REPAIR  
ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.29 – ROTOR REMOVAL  
BRUSH HOLDER BRACKET  
BRUSH HOLDER ASSEMBLY  
EXCITER ROTOR  
NUT  
WASHER  
SLEEVE COLLAR  
PROCEDURE  
Rotor Removal  
1. Turn off the engine.  
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  
2. Open either, or both of the doors on the control  
panel end of the SAE-400 machine.  
7. Bend the washer away from the rotor lock nut.  
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.  
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.  
NOTE: The sleeve collar will have to be removed with  
a small gear puller. Be very careful not to  
damage the rotor slip ring assembly.  
3. Disconnect the battery cables. Disconnect the neg-  
ative cables first, and then disconnect the positive  
cables.  
9. Remove the rotor by pulling it off of the generator  
shaft. If necessary, remove the screws and nuts  
securing the lower front panel. This will allow the  
panel to be shifted enough to provide the additional  
clearance needed to remove the rotor.  
4. Remove the three nuts holding the battery retainer  
bracket. Remove the bracket and the batteries.  
5. Remove the 5 screws securing the exciter covers,  
and then remove the upper and lower covers.  
SAE-400 SEVERE DUTY  
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F-79  
F-79  
TROUBLESHOOTING AND REPAIR  
ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued)  
Rotor Replacement:  
1. Clean and inspect the armature shaft, the exciter  
rotor and slip rings. Replace the rotor if it is dam-  
aged, or if the slip rings are excessively worn.  
9. Mount the brush holder bracket assembly to the  
exciter stator frame 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.  
2. Carefully slide the rotor onto the armature shaft.  
NOTE: It is recommended that a new sleeve collar,  
washer and locking nut be used when installing  
the exciter rotor.  
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-  
paper around the circumference of the slip rings in  
the direction of rotation only. Repeat this proce-  
dure until the brushes are contoured to match the  
radius of the slip rings.  
3. Install the sleeve collar; if necessary, carefully tap  
the collar into place. Be careful that the collar is not  
damaged or deformed.  
4. Install the washer, then the locking nut. Gently  
tighten the nut and check that the rotor is fully seat-  
ed and turning concentric on the shaft.  
11. Attach the wires to the brush terminals. Proper  
polarity is important  
NOTE: On this machine, and all other Lincoln Electric  
DC generator machines, the black exciter lead  
is positive, and the red lead is negative.  
5. Torque the nut to 175 Ft-Lbs.  
12. If necessary, secure the lower front panel.  
6. Bend the washer down to lock the nut in place.  
13. Install the exciter covers and batteries. Reconnect  
the battery cables; connect the positive cables  
first, followed by the negative cables.  
7. Check the rotor air gap. At the smallest point, the  
gap should be wide enough to allow a .016 thick, ½”  
wide feeler gage to pass between the rotor and sta-  
tor.  
14. Close the side doors if the work on the machine is  
finished.  
8. Check the slip rings, brushes and brush holder  
assembly. These parts must be clean and undam-  
aged.  
SAE-400 SEVERE DUTY  
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F-80  
F-80  
NOTES  
SAE-400 SEVERE DUTY  
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F-81  
F-81  
TROUBLESHOOTING AND REPAIR  
ALTERNATOR STATOR REMOVAL AND REPLACEMENT  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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 aid the repair technician in removal and replacement of the exciter  
alternator stator.  
MATERIALS NEEDED  
Miscellaneous Hand Tools  
Pry Bar  
Wiring diagram  
SAE-400 SEVERE DUTY  
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F-82  
F-82  
TROUBLESHOOTING AND REPAIR  
ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.30 – GENERATOR COVER REMOVAL  
GENERATOR COVER  
FOUR SCREWS TOTAL  
6. Lift the eight welding generator brushes from the  
commutator. Note the position of the brushes for  
later reassembly.  
PROCEDURE  
1. Turn off the engine.  
7. To assure accurate reconnection, 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.  
2. Perform the Alternator Rotor Removal  
Procedure.  
3. Remove the roof and doors.  
4. Remove the four covers protecting the welding gen-  
erator brushes. See Figure F.30  
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 necessary to allow the front  
panel to be moved. Most wiring can remain con-  
nected. Be sure to carefully mark all of the wires  
that were disconnected to aid in reassembly. The  
emergency shut down cable will also need to be  
removed.  
5. Use the wiring diagram to identify all of the wires  
connected to the alternator stator winding.  
Carefully mark these leads, for later reassembly,  
and then disconnect them. Cut cable ties as need-  
ed.  
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F-83  
F-83  
TROUBLESHOOTING AND REPAIR  
ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.31 – ROCKER & MARK LOCATIONS  
SPRINGS  
BRUSH HOLDER PLATE  
BRUSH HOLDER  
INSULATORS  
MOUNTING SCREW  
DRILL MARK  
ROCKER  
COMMUTATOR  
ARMATURE  
BRUSHES  
BRUSH RETAINER  
PROCEDURE (continued)  
10. Loosen the rocker clamping screw, but do not  
remove it.  
9. Drain the fuel and store it in an approved container.  
Disconnect the fuel line from the bottom of the tank  
and plug the line to avoid getting dirt or other cont-  
aminants into the fuel system. Remove the fuel  
tank and the tank mounting rails.  
11. Use a hoist, or other appropriate means to support  
the weight of the exciter frame assembly.  
Note the drill spots marking the position of the exciter  
bracket and the rocker. It is very important that these  
marks be precisely aligned during reassembly. See  
Figure F.31  
12. Remove the four screws securing the exciter end  
bracket to the generator frame.  
13. Carefully pry the exciter stator/end bracket assem-  
bly away from the generator frame.  
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.  
NOTE: The welding generator brush holder and rocker  
assembly will also be removed.  
SAE-400 SEVERE DUTY  
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F-84  
F-84  
TROUBLESHOOTING AND REPAIR  
ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued)  
Replacing the Exciter Alternator Stator:  
1. During reassembly, anti-seize compound should be  
applied to the screw threads.  
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.  
2. Inspect the mating surfaces of the generator frame  
and the exciter bracket assembly. These surfaces  
must mate together completely so it is very impor-  
tant that the surfaces are completely clean and  
undamaged. The bearing and bearing housing  
should also be clean and undamaged.  
9. If the original brushes are used, install them in the  
same positions that they had been. Form the braid-  
ed brush leads so they will not interfere with the  
travel of the brushes as they wear.  
Be sure that the rocker assembly is placed on the bear-  
ing housing with the locking screw positioned on top.  
10. Reverse the removal procedure to finish reassem-  
bling the machine.  
3. Place some bearing grease in the bearing housing.  
Chevron SRI or equivalent is recommended.  
11. Replace all the tie wraps that had been removed  
during disassembly.  
4. Mount the exciter stator/end bracket assembly to  
the welding generator frame. Carefully line up the  
drill spot between the two mating parts. Carefully  
and evenly tighten the four mounting bolts. See  
Figure F.31.  
12. Replace and connect the batteries. Connect the  
positive cables first, followed by the negative  
cables.  
13. Connect the fuel line and fill the tank. The fuel sys-  
tem may require bleeding. See the engine instruc-  
tion manual for more information on the fuel sys-  
tem bleeding procedure.  
5. Check the armature air gap. At the smallest point,  
the gap should be wide enough to allow a .030”  
thick ½” wide feeler gage to fit between the arma-  
ture and stator through the entire length.  
14. Start the engine and seat the brushes using a  
commutator stone. See the commutator and  
brush service procedure.  
6. Position the rocker tightly against the hub, align the  
drill mark and tighten the rocker lock screw to 70 to  
75 Inch-Lbs. DO NOT OVERTIGHTEN.  
15. Replace the brush and exciter sheet metal covers.  
16. Replace the roof and doors.  
7. Be certain that the brush holders are properly posi-  
tioned and parallel with the commutator. See the  
commutator and brush service procedure.  
SAE-400 SEVERE DUTY  
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F-85  
F-85  
TROUBLESHOOTING AND REPAIR  
GENERATOR FRAME REMOVAL AND REPLACEMENT  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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 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  
SAE-400 SEVERE DUTY  
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F-86  
F-86  
TROUBLESHOOTING AND REPAIR  
GENERATOR FRAME REMOVAL AND REPLACEMENT (continued)  
PROCEDURE  
Remove the generator frame  
9. Carefully pry and wiggle the generator frame to free  
it from the adapter plate, and then slide the genera-  
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.  
1. Turn off Engine.  
2. Perform the Alternator Rotor Removal  
Procedure.  
Replacing the Generator Frame  
3. Perform the Alternator Stator Removal  
1. During reassembly, anti-seize compound should be  
applied to the screw threads.  
Procedure.  
4. Disconnect all of the wires and cables that connect  
to the stator/frame assembly. Carefully mark them  
for reassembly.  
2. Carefully inspect the mating surfaces of the engine  
adapter plate and the generator frame. The mating  
surfaces must be clean and undamaged.  
5. Remove the mounting bolts from the generator feet.  
3. Lift the generator frame with the rope sling and very  
carefully slide it over the armature. Be very careful  
that the armature and stator windings are not dam-  
aged.  
6. Using a hoist and sling, very carefully lift the gener-  
ator only enough so the generator frame will clear  
the welder frame and can be removed. The sling  
should be positioned near the center of the genera-  
tor frame.  
4. Align the bolt holes and install the screws that had  
been removed earlier. Carefully and evenly tighten  
them, making sure that the mating surfaces come  
together cleanly all the way around. Tighten the  
screws; see the torque specification page for cor-  
rect torque values.  
Carefully watch the clearance between the engine and  
any other components while hoisting, especially the  
clearance between the engine fan, the fan shroud, and  
radiator. Loosen or remove the radiator if necessary.  
5. Remove the supports from the engine and carefully  
lower the generator frame. Install the rubber  
mounts.  
7. Support the engine at the generator adapter plate  
end.  
6. Reverse the removal procedure to reassemble the  
machine. Be sure to secure all cables, and wires.  
Replace all cable ties that had been removed dur-  
ing disassembly.  
8. With the generator frame still supported by the  
sling, (Be certain the sling is positioned at the cen-  
ter of gravity of the generator frame.) and the weight  
of the engine resting on the supports that were  
placed in the previous step, remove the screws  
securing the generator frame to the engine adapter  
plate.  
7. Perform the Alternator Stator Replacement  
Procedure.  
8. Perform the Alternator Rotor Replacement  
Procedure.  
SAE-400 SEVERE DUTY  
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F-87  
F-87  
TROUBLESHOOTING AND REPAIR  
GENERATOR ARMATURE REMOVAL AND REPLACEMENT  
WARNING  
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 technician  
or machine operator and will invalidate your factory warranty. For your safety and to avoid  
electrical shock, please observe all safety notes and precautions detailed throughout this  
manual.  
If for any reason you do not understand the test procedures 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  
SAE-400 SEVERE DUTY  
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F-88  
F-88  
TROUBLESHOOTING AND REPAIR  
GENERATOR ARMATURE REMOVAL AND REPLACEMENT (continued)  
FIGURE F.32 – SLING LIFT  
ROPE SLING  
BLOWER PADDLE  
BLOWER  
PADDLE/ARMATURE  
MOUNTING BOLTS (8)  
PROCEDURE  
Removing the Armature  
Replacing the armature  
1. Carefully inspect the mating surfaces of the fly-  
wheel and armature coupling parts. These surfaces  
must be clean and undamaged.  
1. Turn off the engine  
2. Perform the Alternator Rotor Removal  
Procedure.  
2. Support the armature in a rope sling and carefully  
move it into position, and align it to the flywheel.  
3. Perform the Alternator Stator Removal  
Procedure.  
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 plate is fully  
and cleanly seated in the flywheel.  
4. Perform the Generator Frame Removal  
Procedure.  
5. Using the rope sling, support the armature. Position  
the sling at the center of gravity of the armature  
assembly. See Figure F.32  
4. Replace the eight screws and four blower seg-  
ments. Tighten the screws per the torque specifica-  
tion sheet.  
6. Remove the eight screws securing the blower pad-  
dle segments and the outer diameter of the flexible  
coupling disk to the flywheel.  
5. Perform the Generator Frame Replacement  
Procedure.  
7. With the armature securely supported in the sling,  
unlock it from the flywheel by carefully rotating it 1/8  
of a turn in either direction.  
6. Perform the Alternator Stator Replacement  
Procedure.  
7. Perform the Alternator Rotor Replacement  
Procedure.  
SAE-400 SEVERE DUTY  
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F-89  
F-89  
RETEST AFTER REPAIR  
Retest after repair  
The machine should be retested if any parts are replaced that could affect the machine’s  
electrical characteristics.  
Engine output:  
Perform the Engine RPM Adjustment Test  
Welder DC Output:  
Maximum Output:  
Bring the machine to normal temperature by connecting a load bank and operating the  
machine at 100% output (400 amps @ 36 volts) for about 30 minutes.  
Remove the load and set the output control and job selector rheostat to the maximum posi-  
tion.  
IMPORTANT: Do not move the output control while a load is applied to the weld out-  
put 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 operating at normal operating temperature.  
Place the idle switch in the high idle position.  
230 Volt receptacles should read 240 to 254 AC volts.  
115 Volt receptacles should read 118 to 128 AC Volts.  
Field amps and volts:  
Place the Job Selector rheostat to Maximum. (The machine should still be at normal operat-  
ing temperature.)  
Exciter volts, Measured at slip rings: 124 to 132 DC Volts  
Exciter rotor amps: 2.1 to 2.6  
Shunt field amps: 2.55 to 3.2  
(Measure the Shunt Field current at either the blue or brown wires between the generator  
and the 500 ohm resistor. See wiring diagram.)  
SAE-400 SEVERE DUTY  
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G-1  
G-1  
TABLE OF CONTENTS - DIAGRAM SECTION  
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1  
Wiring Diagram - Control - Code 10856 (M19237) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2  
Wiring Diagram - Engine - Code 10856 (M20609) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3  
Wiring Diagram - Code 11199 (M20544) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4  
Wiring Diagram - Code 11408 (M21283) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5  
Wiring Diagram - 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 Board Assemblies are now totally encapsulated and are therefore considered to be  
unserviceable. The Assembly drawings are provided for reference only.  
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-2  
G-2  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - CONTROL - CODE 10856 (M19237)  
1 9 M 2 3 7  
REVISEDLEADB TO11 ONCB3TOCB4  
HANGE DETAIL:  
C
ENGINEERIN  
G
CONTROLLED  
M
ANUFACTURER: No  
CONT  
R
OL WIRIN  
G
D
IAGRAM -  
S
AE-400  
&
WELD'N  
A
IR  
REMOTE CONTROL RECEPTACLE  
P
LUG FOR REMO  
T
E CON  
Y
T
ROL  
PO  
T
EN  
T
IOMETER  
AC  
COLOR CODE  
AND SWITCH  
G
W
203  
G
ALTERNATO  
R
B-BLACK O  
G-GREE  
N-BROWN  
R-RE  
U-BLUE  
R
GRAY  
R
OTOR  
X
G
X
N
+
RESISTORS  
-
D2  
AC  
B
R
Y
(-)  
(+)  
S
LI  
P
RINGS  
W
D
O
R
PINK  
W
R
U
600  
41  
FLASHIN  
G
D
IODE  
AN  
D
RESISTOR  
W-WHITE  
Y-YELLOW  
W
R
G
600A  
41A  
1
2
3
4
5
R
W
G
238  
42  
602  
42A  
NE  
G
3
POS  
B
1
W
SEE BATTER  
Y
W
-
+
CONNEC  
T
B
WIRIN  
G
D
IAGRA  
M
T
O BASE  
6
R
4
GROUND  
B
REMO  
TE CONTROL  
2
P8  
PO EN  
T
T
IOME  
T
ER BOX  
SCREW  
(+)  
TO LO  
WER PANEL  
201  
G
SWITCH FO  
R
LOCAL OR  
GROUND SCRE  
W
Y
REMOTE CONTROL SHOWN  
U
AC  
AC  
POLARIT  
Y
IN LOCA  
L
POSITION.  
D1  
602A  
500  
U
SWITCH  
1
4
R
G
(-)  
2
3
W
R
G
G
602B  
WHITE  
4
230V DUPLE  
X
5
T
ERMINALS  
RECEPTACLE  
602  
U
N
BACK VIE  
W
ALTERNATO  
AU ILIAR  
PO  
R
REACTO  
R
R
W
OF POLARIT  
Y
X
Y
B
SWITCH  
REMOTE SWITCHWIREDTHIS  
WAY ON EARLIER UNITS  
W
ER WDG.  
W
115V DUPLEX  
F
E
RECEPTACLE  
A
2
FRONT VIE  
W
1
OF RECEPTACLES  
B
3
B
15A  
15A  
20A  
20A  
B
B
ELECTR  
TO WORK TERMINAL  
ODE  
TOROID  
2CR  
W
R
SEE BATTERY  
WIRING DIAGRAM  
CB1  
CB3  
CB4  
CB2  
B
W
W
ELD CURRENT  
B
11  
SENSI G S ITCH  
N
W
R
ELECTRICAL SYMBOLS PER E1537  
C
M19237  
THIS DOCUMENT CONTAINS PROPRIETARY INFO  
R
MATION O  
W
NED BY  
L
INCOLN GLO  
B
AL  
,
INC. AN  
D
MAY NOT BE DUPLICATED, COMMUNICATED  
PROPRIETARY & CONFIDENTIAL:  
TO  
O
THER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN  
P
ERMISSION OF LINCOLN GLO  
BAL  
,
INC.  
U
NLESS OTHERWISE SPE  
CIFIED  
T
OLERANCE  
DESIGN INFO  
RMAT  
IO  
N
REFERENCE:  
M18827  
MANUFACTURING TOLERA  
N
CE PER E2056  
EQUIPMENT TYPE:  
1
1
ENGINE WELDERS  
WIRING DIAGRAM  
PAGE _  
_
_ OF __  
_
ON  
2
PLACE DEC  
I
MALS IS .0  
2
FEI  
DRAW  
N
BY:  
ON  
3
PLACE DECIMALS IS .002  
DOCUMENT  
REVISION:  
DOCUM  
E
NT  
ON ALL ANGLES IS .5 OF A DEGREE  
SUBJECT:  
CRM34845  
UM M19237  
N
BER:  
MATERIAL TOLERANCE (" ") TO AGREE  
ENGINEER  
:
SCALE  
:
t
WITH  
DS.  
DO NOPTUSBLCISAHED  
L
E TSTHAINSDDARRAWING  
DISPOSITION:  
MATE R IAL  
APPROVAL  
DATE:  
PROJECT  
NUMBER:  
C
UF  
APPROVED:  
-
NONE  
2/20/2004  
NOTE: This diagram is for reference only. It may 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.  
®
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-3  
G-3  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - ENGINE - CODE 10856 (M20609)  
2 0 M 6 0 9  
NEW  
CHANGE DETAIL:  
ENGINEERIN  
G
CONTROLLED  
M
ANUFACTURER: No  
WIRING DIAGRAM - SAE-400 PERKINS  
ENGIN  
IODE  
E
HOUR METER  
GENERAL MAINTENANCE  
I
NSTRUCTIONS  
FOR ENGINE  
AN OTOR DRIVEN ARC WELDING POWER SOURCES.  
D
M
TO FLA  
S
HIN  
G
D
W
238  
-
THERMOSTART  
IGNITER  
WARNING:  
H
ave only qualified personnel  
perform  
THERMOSTART  
B
maintenance work.  
IND  
233  
T
urn the engin  
maintenance wor  
requires it to  
e
o
r
input power OFF  
before  
W
k
unless the maintenance wor  
k
B
b
e
running  
.
237  
B
ERNATOR  
S
TART  
Keep h nds,  
a
h
air, clothing  
rts, and in  
fter servicing.  
a
nd tools away  
224  
ALT  
B
MOVING  
PARTS  
fro  
m
mo ing  
v
p
a
s
ure all gu rd  
a
s
or  
-
B
covers are replace  
d
a
AMMETER  
222  
U
CAN  
I
NJURE  
COLD  
TERMINAL  
IDLER  
SWITC  
IDLER  
234  
G
H
SOLENOID  
B
WARNING  
220  
225  
B
5B  
226  
229  
U
B
U
ncontrol  
l
ed  
r
elease  
of  
d
oor restr  
and keep face away  
hooking or releasing hook.  
aint  
cords can cause injury.  
B
Keep secur  
from cord  
e hold of cord  
hen  
,
IGNITION  
SWITCH  
5A  
G
w
B
235  
MAINT  
ENANCE INSTRUCTIONS  
B
236  
1
2
3
4
10  
J2  
1
2
3
6
7
8
9
4
5
B
DAILY CHECKS:  
J1  
R
IDLER/EN  
PROTECTION  
P.C. OARD  
GINE  
Welding cable connections are tight.  
B
R
G
All  
equipment in serviceable condition  
.
Engin  
e
o
il, cool nt, air cleaner and fuel  
a
5C  
s
tr iner are at proper operating level and clean.  
a
S
AS REQUIRED:  
Blo du t from machin  
W
w
s
e
u
s
ing clean lo  
w
pressure air.  
W
O
IL PRESSUR  
E
STARTING  
MOTOR  
-
-
Clea ommut tor r slip  
NOT EMERY CLOTH. See Operating Manual fo  
n
c
a
s
o
r
ings with ine sandpaper-  
f
SWITCH (N.C.)  
B
G
r
in tru  
s
c
tions.  
TO  
C
O
NTR  
O
L
PANEL  
GROUND  
S
CREW  
Replace rushes for th igtails are within 1/4"of  
b
b
e
e
e
p
B
B
223  
221  
1/4" of the commut tor See Operating Manual fo in  
a
.
r
stru tions.  
c
TO TOROID  
R
B
227  
LEAD COLOR CODE  
B
2
D
C
R
G
FU  
E
L
S
HUT  
B-BLACK OR GRA  
Y
REE  
RELAY  
OFF  
VALVE  
G-GREEN  
TEMPERATURE GAGE  
N-BROWN  
R-RED OR  
U-BLUE  
PINK  
G
ENGIN  
E
TEMP.  
CASE OF TEMPERATURE GAUGE  
IS GROUND LD ACHINES  
W-WHIT  
E
SENSOR  
O
N
O
ER  
M
Y-YELLO  
W
G
FU L INJECTI PUMP  
E
ON  
B
R
A
M20609  
THIS DOCUMENT CONTAINS PROPRIETARY INFO  
R
MATION O  
W
NED BY  
L
INCOLN GLO  
B
AL  
,
INC. AN  
D
MAY NOT BE DUPLICATED, COMMUNICATED  
PROPRIETARY & CONFIDENTIAL:  
TO  
O
THER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN  
P
ERMISSION OF LINCOLN GLO  
BAL  
,
INC.  
U
NLESS OTHERWISE SPE  
C
IFIED  
CE PER E2056  
MALS IS .0  
PLACE DECIMALS IS .002  
TOLERANCE  
DESIGN INFO  
RAW BY:  
ENGINEER  
APP OVED:  
RMAT  
IO  
N
REFERENCE:  
M19233  
MANUFACTURING TOLERA  
N
EQUIPMENT TYPE:  
1
1
ENGINE WELDERS  
PAGE _  
_
_ OF __  
_
ON  
ON  
2
3
PLACE DEC  
I
2
FEI  
D
N
DOCUMENT  
REVISION:  
DOCUMENT  
ON ALL ANGLES IS .5 OF A DEGREE  
SUBJECT:  
WIRING DIAGRAM(BATTERY CIRCUIT #1)  
CRM36634  
UM M20609  
N
BER:  
MATERIAL TOLERANCE (" ") TO AGREE  
:
SCALE  
:
t
WITH  
DS.  
DO NOPTUSBLCISAHED  
L
E TSTHAINSDDARRAWING  
DISPOSITION:  
MATE R IAL  
APPROVAL  
DATE:  
PROJECT  
NUMBER:  
A
TRP  
NA  
R
-
NONE  
1/6/2005  
S
NOTE: This diagram is for reference only. It may 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.  
SAE-400 SEVERE DUTY  
®
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G-4  
G-4  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - CODE 11199 (M20544)  
2 0 M 5 4 4  
CHANGE DETAIL: CHANGEDCB4 TO CB5.  
ENGINEERIN  
G
CONTROLLED  
M
ANUFACTURER: No  
SAE 400 / SAE 400SD WIRING DIAGRAM  
CONTROL PANEL COMPONENTS SHOWNAS VIEWEDFROMREAR.  
LEADS CONNECTEDTOENGINE IDLER/ENGINE P.C. BOARD, SEE DETAIL  
NEUTRAL BONDED TO FRAME.  
NEUTRE RACCORDE AU BATI.  
REMOTE CONTROL  
Y
G
*
X
GND-A  
B1  
G
212D  
212C  
59  
1
2
3
4
5
IDLER/ENGINE PROTECTION P.C BOARD  
.
PLUG FOR  
REMOTE CONTROL  
POTENTIOMETER  
U
W
B3  
61  
RESISTORS  
B4  
LEAD COLOR CODE  
55  
J31  
6
7
844A  
44  
54  
57  
58  
238A  
B-BLACK OR GREY  
G-GREEN  
N-BROWN  
R-RED OR PINK  
U-BLUE  
W-WHITE  
844  
8
B2  
J33  
J32  
REMOTE CONTROL  
POTENTIOMETER BOX  
9
1
2
3
4
5
6
1
2
3
4
10  
CONNECT TO BASE  
TO CURRENT  
TRANSFORMER  
FLASHING DIODE  
AND RESISTOR  
REMOTE CONTROL  
RECEPTACLE  
AC  
D2  
238  
203  
(-)  
G
AND SWITCH  
58H  
GND-F  
FUEL  
PUMP  
X
(+)  
*58  
ALTERNATOR  
ROTOR  
+
B
R
Y
ENGINE TEMP.  
SENSOR  
GND-D  
-
FUEL INJECTIONPUMP  
AC  
W
600  
41  
R
GLOWPLUGS  
IDLER  
SOLENOID  
212F  
SLIP RINGS  
IDLER  
SWITCH  
600A  
W
B
W
R
41A  
42A  
1
2
3
4
5
6
*55  
*57  
*844A  
42  
602  
ENGINE  
NEG  
-
POS  
22  
4
21  
IGNITION  
SWITCH  
FAILURE  
LAMP  
*61  
+
53  
201A  
602A  
202  
TEMPERATURE  
GLOW  
START  
PLUG  
ENGINE  
201  
AC  
CB5 SWITCH/SENDER  
1
2
HOUR  
3
P8  
238  
10A  
56  
212A  
(+)  
SWITCHFOR LOCAL OR  
REMOTE CONTROL SHOWN  
IN LOCAL POSITION.  
ME TE R  
W
G
+
-
AC  
43  
215  
214  
POLARITY  
SWITCH  
50B  
52  
*44  
D1  
(-)  
*238A  
50A  
602A  
500  
5C  
S
5B  
51A  
I
41A  
WATER  
TEMPERATURE  
GAUGE  
1
GND-N  
G
GND-C  
2
3
4
TO IDLER  
P.C. BD.  
602C  
203A  
RHEOSTAT  
602B  
212B  
GND-T  
GND-R  
820  
GND-S  
GND-M  
5
4
200  
N
BACK VIEW  
OF POLARITY  
SWITCH  
810  
I
S
WHITE  
STA  
R
TING  
A
MMETER  
U
ALTERNATOR  
AUXILIARY  
POWER WDG.  
7A  
REACTOR  
-
*54  
WK  
+
M
OTOR  
TERMINALS  
115V DUPLEX  
RECEPTACLE  
G
S
OIL  
PRESSURE  
GAUGE  
G
OIL PRESSURE  
SWITCH/SENDER  
B
50  
230V DUPLEX  
RECEPTACLE  
*59  
CB3  
20A  
F
4A  
CB2  
15A  
CB4  
20A  
E
+
TOROI  
D
CB1  
A
LTERNATOR  
A
400F  
6A  
11A  
2
B+ D+  
15A  
1
51  
5B  
11  
5C  
GND-  
GND-E  
TO WORK  
TERMINAL  
ELECTRODE  
11B  
GND-B  
GND-C  
D
-
2CR  
GND-E  
*844  
*GND-A  
WELDCURRENT  
R
B
M20544  
THIS DOCUMENT CONTAINS PROPRIETARY INFO  
RMATION O  
W
NED BY  
L
INCOLN GLO  
B
AL  
,
INC. AN  
D
MAY NOT BE  
D
UPLICATED, COMMUNICATE  
PROPRIETARY & CONFIDENTIAL:  
TO  
O
THER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.  
NOTE: This diagram is for reference only. It may 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.  
SAE-400 SEVERE DUTY  
®
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-5  
G-5  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - CODE 11408 (M21283)  
2 1 M 2 8 3  
CHANGE DETAIL: New  
ENGINEERIN  
G
CONTROLLED  
M
ANUFACTURER: No  
SAE 400 / SAE 400SD WIRING DIAGRAM  
CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROMREAR.  
LEADS CONNECTED TO ENGINE IDLER/ENGINE P.C. BOARD, SEE DETAIL  
NEUTRAL BONDED TO FR AME.  
NEUTRE RACCORDE AU BATI.  
REMOTE CONTROL  
Y
G
*
X
GND-A  
B1  
G
212D  
212C  
59  
1
2
3
4
5
IDLER/ENGINE PROTECTION P.C  
.
BOARD  
PLUG FOR  
REMOTE CONTROL  
POTENTIOMETER  
U
W
B3  
61  
RESISTORS  
B4  
LEAD COLOR CODE  
55  
J31  
6
7
844A  
44  
54  
57  
58  
238A  
B-BLACK OR GREY  
G-GREEN  
N-BROWN  
R-RED OR PINK  
U-BLUE  
W-WHITE  
844  
8
B2  
J33  
J32  
REMOTE CONTROL  
POTENTIOMETER BOX  
9
1
2
3
4
5
6
1
2
3
4
10  
CONNECT TO BASE  
TO CURRENT  
TRANSFORMER  
FLASHING DIODE  
AND RESISTOR  
REMOTE CONTROL  
RECEPTACLE  
AC  
D2  
238  
203  
(-)  
G
AND SWITCH  
58H  
GND-F  
FUEL  
PUMP  
X
(+)  
*58  
ALTERNATOR  
ROTOR  
+
B
R
Y
ENGINE TEMP.  
SENSOR  
GND-D  
-
FUEL INJECTION PUMP  
AC  
W
600  
41  
R
GLOW PLUGS  
IDLER  
SOLENOID  
212F  
SLIP RINGS  
IDLER  
SWITCH  
600A  
W
B
W
R
41A  
42A  
1
2
3
4
5
6
*55  
*57  
*844A  
ENGINE  
42  
602  
NEG  
-
POS  
22  
4
21  
IGNITION  
SWITCH  
FAILURE  
LAMP  
*61  
+
53  
201A  
602A  
202  
TEMPERATURE  
GLOW  
START  
PLUG  
ENGINE  
201  
AC  
CB5 SWITCH/SENDER  
1
HOUR  
3
2
P8  
238  
10A  
56  
212A  
(+)  
SWITCH FOR LOCAL OR  
REMOTE CONTROL SHOWN  
IN LOCAL POSITION.  
ME T E R  
W
G
+
-
AC  
43  
215  
214  
POLARITY  
SWITCH  
50B  
52  
*44  
D1  
(-)  
*238A  
50A  
602A  
500  
5C  
S
5B  
51A  
I
41A  
WATE R  
TEMPERATURE  
GAUGE  
1
GND-N  
G
GND-C  
2
3
4
TO IDLER  
P.C. BD.  
602C  
203A  
RHEOSTAT  
602B  
212B  
GND-T  
GND-S  
GND-R  
820  
GND-M  
5
4
200  
N
BACK VIEW  
OF POLARITY  
SWITCH  
810  
I
S
WHITE  
STA  
R
TING  
A
MMETER  
U
ALTERNATOR  
AUXILIARY  
POWER WDG.  
7A  
REACTOR  
-
*54  
WK  
+
M
OTOR  
TERMINALS  
115V DUPLEX  
RECEPTACLE  
G
S
OIL  
PRESSURE  
GAUGE  
G
OIL PRESSURE  
SWITCH/SENDER  
B
50  
CB1  
15A  
11A  
230V DUPLEX  
RECEPTACLE  
*59  
F
4A  
400F 20A  
E
6A  
CB3  
20A  
CB2  
+
TOROI  
D
A
LTERNATOR  
A
2
B+ D+  
1
7A  
810  
51  
5B  
N
11  
11A  
GND-  
5C  
GND-  
GND-E  
TO WORK  
TERMINAL  
ELECTRODE  
11B  
GND-B  
GND-C  
D
-
2CR  
GND-E  
*844  
*GND-A  
WELDCURRENT  
R
A
M21283  
THIS DOCUMENT CONTAINS PROPRIETARY INFO  
R
MATION O  
W
NED BY  
L
INCOLN GLO  
B
AL  
,
INC. AN  
D
MAY NOT BE  
DUPLICATED, COMMUNICATED  
PROPRIETARY & CONFIDENTIAL:  
TO  
O
THER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN  
P
ERMISSION OF LINCOLN GLO  
B
AL  
,
INC.  
U
NLESS OTHERWISE SPE  
C
IFIED  
CE PER E2056  
MALS IS .0  
PLACE DECIMALS IS .002  
TOLERANCE  
DESIGN INFO  
RAW BY:  
ENGINEER  
APP OVED:  
R
MA  
T
IO  
N
REFERENCE:  
M20544  
MANUFACTURING TOLERA  
N
EQUIPMENT TYPE:  
SUBJECT:  
1
1
ENGINE WELDERS  
WIRING DIAGRAM  
PAGE _  
_
_ OF __  
_
ON  
ON  
2
3
PLACE DEC  
I
2
Magliett  
a
D
N
DOCUMENT  
REVISION:  
DOCUMENT  
ON ALL ANGLES IS .5 OF A DEGREE  
N
BER:  
UMM21283  
A
MATERIAL TOLERANCE (" ") TO AGREE  
:
C
.
KOCSIS  
SCALE  
:
t
WITH  
DS.  
DO NOPTUSBLCISAHED  
L
E TSTHAINSDDARRAWING  
DIS POS ITION:  
MAT E R I AL  
NA  
APPROVAL  
DATE:  
PROJECT  
CRM37526  
NUMBER:  
R
NONE  
10/05/2006  
NOTE: This diagram is for reference only. It may 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.  
SAE-400 SEVERE DUTY  
®
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-6  
G-6  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - GENERATOR FRAME (M5570)  
NOTE: This diagram is for reference only. It may 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.  
SAE-400 SEVERE DUTY  
®
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-7  
G-7  
ELECTRICAL DIAGRAMS  
SCHEMATIC - COMPLETE MACHINE - CODE 10856 (G5351)  
1
3 5 G 5  
E
NGI  
N
EERING CONTROLLE  
D
CHANGE  
DETAIL:  
Revised  
(SHOWN IN  
NEGATIV  
OISTION)  
MANUFACTURER:  
Yes  
P
S
OL  
WITCH  
ARITY  
E
GENERATOR SHUNT  
FIELD CIRCUIT  
TO D1  
POST  
P
AC  
4
R
B
FROM  
HOU MT  
TERMI AL  
N
U
Y
TO  
R-T  
P
C
BD  
2
R
R
+
AUXILIARY POWER  
CIRCUIT  
242  
240  
E
RMI AL  
N
35  
800V  
A
500 OHMS  
50  
located behind uppe  
on rol pane on reactor bo  
N
TO D1  
AC POSTS  
W
203  
REMOTE RECEPTACLE  
W
R
B
C
OMPRESSOR  
1
r
+
-
D2  
ENABL  
loacted lower  
ront pane  
E
c
t
l
x
located behind uppe  
r
U
3
f
l
SWITCH  
c
on  
t
rol pane  
l
on  
located  
l
ower Lt hand  
A
ND PLUG  
reactor bo  
x
side of con rol pane  
t
l
AUXILIARY OUTPUT  
R
ELAY  
CENTER OFF =NO WELD OUTPUT  
X
B
-TERMINAL  
ROTOR FIELDAND  
FLASH CIRCUIT  
85  
30  
X
n.c.  
OCV  
115/230 VAC  
+
10%  
@
1800RPM  
n.c.  
R
Y
t
op right of  
EXCITER  
WINDING  
MAX LOAD  
3KW  
@
100% D.C.  
239  
B
FROMAM-  
genera  
t
f
me  
GENEoRr AraT  
O
P8-1  
located behind  
lo er on rol  
pane  
600A  
P8-2  
600  
87a  
G
-TERMINAL  
no  
MET  
E
R
+
w
c
t
15A  
230V  
RECEPTACLE  
alt  
erna  
t
or  
&
ro  
t
or  
located at  
G
Y
G
diodes  
uppercon  
l
ocated behind  
41A  
R
41  
POST  
l
87  
86  
CB2  
endofgenera  
t
or  
t
rol pane  
l
B
LEAD  
BLOCK  
BRUS  
VIEWE  
H
POSITI  
O
N
SHOWN  
AS  
64  
150 W  
o
hms +/- 6.4  
R
B
B
UPPER  
P
ANEL  
10A  
41.5 ohms +/- 1. 0  
25  
ALTERNATOR  
OTOR  
D
F
R
OMCONTR  
OL PANEL  
UPPER  
GND  
P
ANEL  
GND  
SCREW  
@
C
FUSE  
cc  
w
S
CREW  
located behind  
Y
-TERMINAL  
G
G
UPPER  
P
ANEL  
lo  
w
er  
c
on  
t
rol  
U
R
LOWER  
GND  
P
ANEL  
CREW  
E
F
GND  
S
CREW  
pane  
l
max  
R
R
B
S
A
&
RMATURE  
n.c.  
2
AUXILIARY  
WI DINGS  
LO  
EMOT  
WITCH  
C
AL/  
25OHM  
50  
x3  
BRUSHES  
R
243  
W
N
R
S
E
MI  
N
rheo  
MAX rheo  
=
=
54vdc  
140vdc  
W
-TERMINA  
140vdc  
loacted lower  
ront pane  
L
PRESSURE  
WITCH  
W
W
W
f
l
-
D1  
S
(SHOWN IN  
LOCAL  
N
SERI  
E
S
FIEL  
D
W
A
G
1
-
+
-
SHUNT  
FIEL  
42  
G
B
PeOdSl ITION)  
D
OPTIONAL REMOTE  
CONTROL BOX  
N
S
N
S
C
OMPRESSOR  
CIRCUIT AM  
N=ACTIVE  
locat ower  
rol pane  
m
iddl  
e
602  
CURRENT  
SENSE  
TO OI  
35  
800V  
A
382-40.6 ohms  
25C  
.
W
G
of con  
t
l
L
P
P8-3  
located behind upper  
N
@
+
20A  
20A  
+
c
ontrol panel on  
R
D
B
O
P8-4 MI  
N
rheo  
=
86vac  
115V  
RECEPTACLE  
P
OLES  
CB4  
C
OMPRESSOR  
reactor box  
42  
A
B
MAX rheo=0vac  
CLUTCH  
B
B
located upperLt  
hand side behind  
241  
W
LOWER  
P
ANEL  
JO on  
EL  
64  
B
CB3  
CB1  
c
trol panel  
602  
A
GND  
SCREW  
B
B
S
N
N
max  
S
WE LDING  
GENERATOR  
S
E
CTOR  
TO PCB  
J2  
B
cc  
w
o
6.4  
hms +/-  
R
HEOSTAT  
201  
B
TO  
R-T  
P
RMI  
C
BD  
NAL  
ERG  
UP PANEL  
GND SCREW  
UP ER PANEL  
P
TO D1  
P
150 W  
E
602  
B
15A  
GND SCREW  
A
C
POST  
WE LD'N AIR AIR COMPRESSOR CIRCUIT  
-
2
CR  
WINDING SPEC'S & RESISTANCES  
EXCITER  
U
WE LD CIR CUIT  
REEDRELAY  
B
VARI  
A
BL  
E
W
located behind  
WINDING  
POWER  
QUADRATURE  
SPEC  
RESISTANCE  
COMPRESSOR OUTPUT  
35CFM 100PSI @ 60% D.C.@ 1400RPM  
150 PSI (11 GALLON TANK)  
REACedTuOpRpe  
w
orkstud  
ALT-214-3C .230 OHMS  
@
@
@
25C  
25C  
25C  
locat  
rRt  
LOWER PANEL  
GND CREW  
DELIVERY  
MAX PRESSURE  
@
ALT-214-3B .560 OHMS  
hand side behind  
S
control panel  
AUXILIARY (TAIL) ALT-214-3D .424 OHMS  
OPERATING PRESSURE LOADS  
@
90 PSI  
ROTOR (4-POLE) ALT-214-3A 41.4+/-1.0 OHMS  
@
25C  
UNLOADS  
@
130 PSI  
DIAGRAM  
M14262  
ou  
rai  
(electrode closest to con  
t
put stud  
s
l
ocated on right fue  
ro on rol pane end)  
rol panel)  
l
tank  
120 OHMS  
2.5W  
GENERATOR  
WOR  
K
ELECTROD  
E
l
(
viewed  
f
m
c
t
l
located behind uppe  
r
INTERPOLE  
SHUNT FIELD  
SERIES FIELD  
ARMATURE  
DIAGRAM  
S12261-25 N/A  
t
c
ontrol panel on  
IDL  
SHUTDOW  
(SCHEM.  
E
R/ENGINE  
PCB  
L11006-2C1)  
located behind lower  
FKL-5AJ  
19.1-20.3 OHMS  
@
25C  
reactor box  
CC WELD OUTPUT  
c
on rol pane  
t
l
N
FKL-420-U N/A  
FKL-37.4M N/A  
M5570  
1A  
INPUTS  
MIN TO MAX OCV 57-97VDC  
@
1800 RPM  
O
UT  
P
UTS  
#
1000  
V
WELD RANGE  
MAX LOAD  
80-575 AMPS  
400A  
@
40V  
@
60% D.C. (1725 RPM)  
30SEC  
T
IMER  
ENGINE  
T
(LOCKS OU  
T
+10v  
+10V  
238  
W
TO EX  
C
T
E
RMI AL  
N
SENSOR S AND IMES LT  
A
Vbatt  
ON  
ENGI  
NE  
ALT  
FLASH A POWER-UP)  
T
602  
SAE400  
OPTIONAL CV ADAPTER  
INTERFACE WITH  
reset  
reset  
hi  
moun  
t
ed on engine block  
OIL PRESS  
WITCH  
lo  
SHO  
ONL  
CV ADAPTE  
W
N
FOR REFERENC  
E
belowfuel pump  
*
10vdc  
=
normal oper  
a
tion  
ENGINE  
FLASH & SENSE  
ALT  
S
Y
-
NOT ACTUALL PAR OF  
Y
T
J1-  
7
*0vdc = shudo  
t
wn  
reset  
SWITCH OPENS  
@
15+/-3PSI  
C
V
ADAPTER  
CONT OL PCB  
(SCHEM. L6922)  
R
224  
t
CV adap  
t
er bo  
x
l
ocated on  
l
eft fue  
l
t
an  
k
located engine star  
at air ntake anifol  
1.0-2.0 ohms  
ter side  
located side CV  
i
n
B
223  
*
11  
.
5-12.9vdc  
J1-  
3
R
located on  
ront pane  
HOUR  
METER  
rai viewed  
l
(
f
ro  
m
c
on rol pane  
t
l
end)  
i
m
d
adapt  
er bo  
x
S1 small  
s
witch  
ENGINE PROTECTION  
SENSE CIRCUIT  
f
l
#
W
O
UT  
P
UT  
S
IN  
P
UT  
S
located on faceof  
TEM  
P
mi  
c
ro  
s
witch  
guag  
SE  
located  
TH RM ST  
E
O
A
RT  
CV adap  
ter bo  
x
*
10vdc  
=
normal operation  
down  
CR1 CONTACTO  
DR IVE INPUT  
R
in  
t
em  
p
e
S
WITCH  
S1  
TH  
E
RM START  
O
+
-
J1-1  
0
IGNITER  
*
11-13vdc  
J1-  
6
*0vdc = shu  
t
TRIP POIN  
G
T
T
AT  
220F +/- 4%  
5
B
Ac  
_
J
1-8  
B
229  
G
+
B
608  
221  
eldcurrent  
FROM  
v
B
233  
*
140vdc  
(J1-8 toJ1-4)  
610  
Y
LOWER PANEL  
GND SCREW  
+10v  
PC  
BD  
vv  
610  
*
10vdc  
=
no  
w
LOWER  
GND  
P
ANEL  
FUE  
DRIVE CIRCUIT  
L
SOLENOID  
*0vdc = weldcurrent, pick up  
to hi dl  
J1-3  
+15VDC  
+
140VDC  
140vdc (w  
/
rheo  
-
SCREW  
2 CR REED  
RELAY  
located engine  
l
eft side  
i
e
stat at ax)  
m
R
510  
FUEL  
I
NJ  
P
UM  
P
(
viewed ro on  
f
m
c
t
rol panel end)  
140vdc  
(J2-3 toJ1-4)  
510  
R
CR1 CONTACTO  
DRIVE CIRCUIT  
R
500 OHMS  
50W  
WE LD  
CURRENT  
SENSE INPUT  
located behind  
orkstud  
C
R1  
4
J
2-  
3
POWER  
SUPPLY  
Vbatt  
R
B
w
LOWER  
P
ANEL  
J
1-3  
COIL  
B
WELD& AUX CURRENT  
SENSE CIRCUIT  
CURRENT  
SENSE  
OID  
224  
2
3
SEC  
24ohms  
606  
23-24vdc  
nCV  
605  
no  
GND  
SCREW  
BOARD  
POWER  
located behind  
on rol pane  
B
600  
TO D1AC  
POST  
U
ENGINE  
T
EMP  
c
t
l
J2-  
3
CR1  
l
ocated  
i
n
side  
203  
4
ohms  
P-CHNL  
+12v  
TO  
R
B
W
i
SWITCH  
*11-13vdc  
25V  
CV adapt  
er bo  
x
*0vdc  
(J2-2 toJ1-4)  
W
1
J
1-7  
2 AMP  
RECTI  
IER  
-
+
J1-9  
J2-  
4
-
D2  
no  
no  
P
OLARITY  
J
2-  
2
G
G
B
227  
B
+
F
PRI  
500  
613  
237  
35  
A
FUE  
L
INJ PUMP  
DO NOTHAVE OVER-  
ROTECTION  
C
OILS  
B
B
IARYW  
AUXIL  
CURRENT  
360-440 OHMS  
25  
SWITCH  
(NO AFFEC W/ CV  
ADAPTER HOOKED UP)  
600  
A
E
XC. OVER-  
VOLTAG  
PROTECTION  
TO P8-2  
800V  
@
C
T
n.c.  
CR1  
l
ocated  
i
n
side  
E
C
R1  
TO  
PC  
BD  
cated on  
L
AMP lo  
CURRENT  
P
ALTERNATOR  
B
CV adap  
t
er bo  
x
229  
ENGI  
N
E
F
A
ULT  
CR1 CONTACTO  
DRIVE RETURN  
R
SENSE INPUT  
LAMP  
DR IVE CKT  
f
ront pane  
l
rst  
CONT CT  
A
S
J1-10  
55AMP AX DRAW  
located engine right side  
viewfro on rol pane  
M
*12-14vdc  
J
1-  
4
IDLER  
SWITCH  
5
_
J1-4  
J1-8  
12SEC  
TIME R  
612  
611  
238  
600  
667  
W
+
G
602  
GENERATOR  
SHUNT FIEL  
5C  
LOWER  
GND  
G
R
U
226  
IGNITION  
WITCH  
(
m
c
t
l
end)  
RT  
+
140VDC  
B
(SHOWN IN  
Vbatt  
+10v  
POWER OUTPUT  
TO SHUNT  
ARC VOLTAGE  
FEEDBACK  
HOUR  
METER  
reset  
hi  
reset  
lo  
AUTO  
I
D
LE  
S
P
ANEL  
CREW  
IDLE DRIVE  
CIRCUIT  
ou  
t
located engine  
viewed ro  
l
eft side  
ST  
WITCH  
A
BUTTON  
LOWER  
GND  
P
ANEL  
J1-  
1
J
1-1  
S
*12-14vdc  
POSITION)  
236  
+15VDC  
FIELD  
J
2-6  
(
f
m
c
on rol pane  
t
l
end)  
D
S
CREW  
POWER  
SUPPLY  
S
509  
B
220  
B
B
reset  
t
B
225  
*8. 6-42vdc  
(J1-1 toJ1-2)  
W
c
v
BOARD  
POWER  
-
+
*S E E WAVE FORM  
(J2-6 toJ2-1)  
J1-  
5
+
15VDC  
AMMETER  
fl
diod  
ywheel  
e
UPPER  
GND  
P
ANEL  
CREW  
10  
8.8 OHMS +/-  
IDLER  
.
5-12.5vdc  
N-CHNL  
74hz  
.
88  
@
25C  
G
PWM  
vv  
S1 small  
located on faceof  
CV adap er bo  
s
witch  
S
OVERCURRENT  
PROT CKT  
1A  
1000  
S1Cvv  
FLYWHEEL  
DIODE  
*
12.9vdc  
(J1-5 toJ1-2)  
5
A
.
J1-  
2
B
V
FLYWHEEL  
DIODE  
S1  
D
J
2-5  
t
x
J
1-  
1-  
1-  
5
S
OLENOI  
PULL OW IDLE  
HI IDLE 1800RPM  
LOW IDLE 1100RPM  
D
503  
LOWER  
GND  
P
ANEL  
77  
S1 small  
located on faceof  
CV adap er bo  
s
witch  
R
B
B
c
v
max  
T
O
L
=
10  
S
CREW  
R3  
35  
A
800V  
J
2-1  
J
6
CV  
V
OLTAGE  
R
120 OHMS  
2.5W  
-
76  
567  
501  
t
x
K
cw  
235  
30OHMS  
100W  
CONT OL OT  
P
=
J
9
CV SWITCH FOR  
FIELD  
SHUN  
DRIVE CIRCUIT  
T
FIELD  
75  
*3. 1vdc  
(J1-9 toJ1-2)  
located on faceof  
CV adap er bo  
SHUNT  
222  
234  
with re  
D1  
U
B
t
x
B
201  
+
+
+
S1  
B
WE LD COMMON  
1/8 AMP  
J
1-  
2
c
12  
ATTERY  
located genera or  
endof achine  
V
OLT  
521  
v
ALTERNATOR  
B
*NOTE  
:
m
ea  
s
urement  
m
ade  
s
pect to frameground  
.
located engine right side  
view fro on rol pane end)  
E
N
GINE  
vv  
R
OTOR  
t
(
m
c
t
l
STARTE  
R
m
S1 small  
located on face of  
CV adap er bo  
switch  
IDLER/ENGINE SHUTDOWN  
CIRCUIT  
S2  
*NOT  
ODE  
128m  
E
:
m
ea  
s
uremen  
t
m
ad  
e
i
nCV ode.  
m
t
x
ENGINE  
B
LOCK  
FRAME  
FRAME  
S2  
l
arge  
s
witch ocated on  
l
face of CVadapter box  
CV  
ADAPTER  
V
OLTAG  
E
WAVEF  
O
RM  
:
J2-6 to J2-  
1
IN  
C
V
M
CONT OL PCB  
R
IDLER/ENGINE SHUTDOWN PC BOARD  
POWER UP SEQUENCE  
POSITIVE  
12.  
8ms  
.
s
621  
positive stud  
rai viewed  
l
ocated on right fue tank  
l
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
Upon receiving power, circuit to flash alternator is closed and  
engine protection is bypassed. After time delay, alternator  
flashing circuit opens up and engine protection is enabled.  
Note!!: After time delay when engine protection is enabled, if  
the engine is not started, oil pressure will be low, the fuel  
solenoid will drop out, and the engine fault light will turn on  
because of the engine protection circuit.  
50-250  
v
50-250v  
l
(
f
ro on rol pane end)  
m
c
t
l
5.2m  
s
.
5m  
s
C
OMPONENT  
CAPACIT R: MFD/  
RESIST R: HMS/  
V
AL  
U
E
U
NITS:  
OLT  
ATT  
IDL  
E
R/ENGIN  
E
SHUTDOW  
N
PCB  
1
LE  
AD  
C
OL  
O
R
CODE:  
GRAY  
666  
R1  
0v  
0v  
J
1
J
25,000  
uf  
C4  
B-BLAC  
K
O
R
O
V
S
MAX  
POT/NO  
L
OAD  
MIN POT/NO LOAD  
1
6
5
2
2
G-GREEN  
O-ORANGE  
R-RE PINK  
U-BLUE  
W- HIT  
O
O
W
S
C1  
C2  
C3  
75v  
x
-
+
-
622  
GENERATOR  
4
D
OR  
CONNECT  
OR  
PIN  
N
UMBERS:  
100 OHMS  
C
ap  
a
ci  
t
or bank an  
d
bleederresistor  
CODE MACHINE DESPCRIPTION  
10601 SAE400 PERKINS 1004.42 DIESEL  
50W  
located  
i
n
side CV adap  
t
er box  
10  
EX. 12PIN CONNECTO  
R
W
E
3
4
+
J
1
Y-YELLOW  
LABELS  
:
J
2
2
1
7
6
10602 SAE400 WELD -N- AIR PERKINS 1004.42 DIESEL  
10856 SAE400 SEVERE DUTY  
CV MODE  
–
POWER UP SEQUENCE  
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.  
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  
C
OMMON  
FRAM  
GROUND  
10884 SAE400 PERKINS (DOMESTIC)  
12  
10885 SAE400 WELD -N- AIR PERKINS (CANADIAN)  
E
LATCH  
drive circuit on PC board at J1 pins  
4
&
8.  
EART  
GROUND  
LINCOLN GLOBAL, INC. AND MA NOT BE DUPLICATED, COMMUNICATED  
THE EXPRES WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.  
H
CR1 closes, applying power to PC board at J2 pins  
and disconnecting flashing circuit.  
2
&
3
CV negstud  
adap er bo  
ue an rai  
on rol pane  
l
ocated on  
ounted on  
viewed ro  
end)  
VIEW OF CONNECTO ONPC BOARD  
R
t
t
t
x
l
m
left  
m
VV negstud  
rai  
l
ocated on right fue tank  
l
C
V
VV  
f
l
k
(
l
f
l
(viewed  
f
ro on rol pane end)  
m
c
t
l
THIS DOCUMENT CONTAINS PROPRIETAR  
Y
INFORMATION OWNED  
B
Y
Y
PC Board PWM circuit regulates output voltage by using  
PROPRIETARY & CONFIDENTIAL:  
NEG.  
c
NEG.  
TO  
O
THER PARTIES OR USED FOR AN  
Y
PURPOS WITHOU  
E
T
S
voltage feedback from J1 pin  
to control current thru the shunt fields.  
Note!!: Rheostat must be set to ma for CV operation.  
1
and control pot at J1 pin  
6
M
ANUFACTURING TO  
L
ERANC  
E
P
ER E2056  
CONTROL: CLEVE  
L
AND  
SCA  
L
E:  
CV WELD OUTPUT  
MIN TO MAX OCV 8-41vdc  
UNLESS OTHERWISE SPECIFIED TOLERANCE:  
EQUIP  
M
ENT TYPE:  
1
1
DOCUMEN  
N
OTE  
!!  
:
WHEN INSTALLING CV ADAPTER,  
NEGATI  
SAE-400  
PAGE ___ OF ___  
T
ON  
ON  
ON  
2
3
PLAC  
E
D
ECIMAL  
S
I
S
.02 in.  
(
0.5 mm)  
NONE  
x
"ELECTRODE" STUDBECOMES VV  
"
VE"  
DRAWN BY:  
ENGINEER:  
APPROVED:  
FE  
I
PLACE  
D
E
CIMALS IS  
.
00  
A
2
i
n.  
(
0.  
0
5
mm)  
T
DOCUMEN  
NUMBER:  
IF PRIN  
T
ED  
WELD RANGE  
MAX LOAD  
15-35vdc  
400A  
500A  
A
LL ANGL  
E
S
I
S
.5 OF  
D
E
GREE  
STUD,& "TO WORK" STUDBECOMES  
"POSITIVE"  
STUD.  
SUBJECT:  
REVISION:  
MACHINE SCHEMATIC  
PROJEC  
NUMBER:  
@
A
1
SIZE  
MATERI  
WITH  
A
L
TO  
L
ERANC  
E
("  
"
)
TO  
A
GREE  
D.  
B
ENDER  
-
t
@
@
35V  
35V  
@
@
60% D.C.  
35% D.C.  
UNIITNSC: H  
LISHED  
DO NOPTUBSCAL  
ANDARD  
REFERENCE:  
-
STTHIS DRS.AWING  
MATERIAL  
DISPOSI ION:  
APPROVA  
L
T
G5351  
NA  
1/1/2000  
B
CRM38346  
T
DATE:  
E
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
®
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-8  
G-8  
ELECTRICAL DIAGRAMS  
SCHEMATIC - COMPLETE MACHINE - CODE 11199 (G4924)  
4
9 2 G 4  
ENGI  
N
EERING CONTROLLE  
D
CHANGE  
DETAIL:  
Revised  
P
S
OL  
WITCH  
ARITY  
MANUFACTURER: No  
(SHOWNIN NEGATIV  
E
POISTION)  
TO D1  
AC  
POST  
GENERATOR SHUNT  
FIELDCIRCUIT  
4
22  
R
AUXILIARY POWER  
CIRCUIT  
2
TO D1  
AC POSTS  
35  
800V  
A
N
U
215  
214  
203  
located behind uppe  
r
500 OHMS  
50W  
1
c
on rol pane on reactor bo  
t
l
x
+
-
D2  
B
3
REMOT  
E
AUXILIARY OUTPUT  
ROTOR FIELDAND  
FLASH CIRCUIT  
located behind uppe  
r
RECEPTACLE  
AND PLUG  
located ower enter  
l
c
OCV  
115/230 VAC  
+
10%  
@
1800RPM  
cont  
rol pane  
l
on  
CENTER OFF =NO WELD OUTPUT  
of con rol panel  
t
EXCITER  
actor bo  
x
ren.c  
203A  
602C  
WI DING  
MAX LOAD  
3KW  
@
100% D.C.  
t
op ht of  
GENEriogRrAraTO  
X
B
-TERMINAL  
N
gene  
t
f
me  
raR  
X
n.c.  
.
15A  
alt  
erna  
t
or  
&
ro  
t
or  
l
ocated at  
diodes  
l
ocated behind  
endof genera  
t
or  
LEAD  
G-TERMINA  
uppercon  
t
rol pane  
l
BRUS  
VIEWE  
H
POSITI  
O
N
SHOW  
N
AS  
600A  
810  
7A  
G
BLOCK  
L
41  
R
B
B
D
F
R
OMCONTR  
OL PANEL  
G
ANEL  
CREW  
G
G
A
P8-2  
600  
UPPER  
GND  
P
ANEL  
ALTERNATOR  
OTOR  
+/- 1. 0 @ 25  
UPPER  
P
230 DUPLE X  
V
64ohms +/- 6.4  
150 W  
S
CREW  
R
m
GND  
S
UPPER ANEL  
P
RECEPTACLE  
E
F
A
&
RMATURE  
BRUSHES  
41.5 oh  
s
C
GND  
SCREW  
cc  
w
2
Y-TERMINAL  
AUXILIARY  
WI DINGS  
Y
U
N
max  
202  
MI  
MAX rheo  
N
rheo  
=
54vdc  
140vdc  
R
R
140vdc  
R
=
SERI  
E
S
FIELD  
-
D1  
n.c  
.
25OHM  
50  
x3  
N
N
A
1
-
W
-TERMINA  
W
W
+
SHUNT  
FIEL  
382-40.6 ohms  
25  
LO  
C
AL  
WITCH  
OCAL  
/
REMOTE  
L
D
35  
A
N
S
S
N
S
W
W
W
.
800V  
(SHOWN IN  
POSITION)  
L
201A  
CURRENT  
SENSE  
TOR  
@
C
located behind uppe  
r
B
-
+
42  
+
20A  
20A  
c
ontrol panel on  
OPTIONAL REMOTE  
CONTROL BOX  
6A  
115 DUPLE X  
V
P
OLES  
OID  
reactor box  
located  
of con rol pane  
lower  
m
l
iddl  
e
CB4  
602  
P8-4 MI  
RECEPTACLE  
W
G
4A  
t
P8-3  
B
B
201  
11B  
N
rheo  
=
86vac  
11  
42  
A
WE LDING  
GENERATOR  
MAX rheo=0vac  
S
N
S
N
B
CB3  
located upperLt  
hand side behind  
B
400F  
B
JOon  
EL  
HE+O/-S6T.4A, T  
B
c
trol panel  
602  
A
UPPER  
GND  
P
ANEL  
CREW  
UPPER  
P
ANEL  
TO  
PC  
BD  
max  
11A  
15A  
G
GND  
SCREW  
S
844-TERMINA  
L
S
ECTOR  
VARI  
A
BL  
E
cc  
w
B
120 OHMS  
2.5W  
WINDING SPEC'S & RESISTANCES  
EXCITER  
2
CR  
R
REACTOR  
64  
W
o
hms 15  
0
located behind uppe  
on rol pane on  
reactor bo  
r
CB1  
WE LD CIR CUIT  
REEeDdREhLiAY  
located upperRt  
hand side behind  
c
t
l
TO D1  
locat be nd  
B
602  
B
x
LOWER  
GND  
P
ANEL  
w
orkstud  
A
C
POST  
WINDING  
POWER  
QUADRATURE  
SPEC  
RESISTANCE  
control panel  
U
1A  
S
CREW  
ALT-214-3C .230 OHMS  
ALT-214-3B .560 OHMS  
@
@
@
25C  
25C  
25C  
1000V  
AUXILIARY (TAIL) ALT-214-3D .424 OHMS  
ROTOR (4-POLE) ALT-214-3A 41.4+/-1.0 OHMS  
@
25C  
DIAGRAM  
M14262  
238  
ou  
rai  
(electrode closest to con  
t
putstud  
s
l
ocated on right fue  
ro on rol pane end)  
rol panel)  
l
tank  
WOR  
K
EL  
E
CTROD  
E
l
(
viewed  
f
m
c
t
l
GENERATOR  
t
INTERPOLE  
SHUNT FIELD  
SERIES FIELD  
ARMATURE  
DIAGRAM  
S12261-25 N/A  
FKL-5AJ  
19.1-20.3 OHMS  
@
25C  
CC WELD OUTPUT  
1800 RPM  
80-575 AMPS  
400A 40V 100% D.C. (1725 RPM)  
TO HOUR  
ETER (+)  
MAY NOT APPEAR ON ALL MODELS  
FKL-420-U N/A  
FKL-37.4N N/A  
M5570  
MIN TO MAX OCV 57-97VDC  
@
M
WELD RANGE  
MAX LOAD  
ENGINE  
TEMPERATURE  
SENSOR  
RI  
G
HT SI  
D
E
OF ENGINE  
UM  
@
@
INJ  
TIMIN  
E
CTI  
O
N
P
UM  
P
ON  
I
NJ CTI  
E
O
N
P
P
G
S
OLENOID  
INJ  
E
CTI  
O
N
P
TY  
UM  
P
TIMING  
P. CURRENT  
APPROX.  
16 HM  
212F  
S
OLENOI  
D
0.9A  
SAE400  
OPTIONAL CV ADAPTER  
INTERFACE WITH  
DRA  
RESISTANC  
W
16  
0.9 AMPS  
O
HM  
S
602  
E
O
S
C
V
ADAPTER  
CONT OL PCB  
(SCHEM. L6922)  
CV adap  
t
er bo  
x
l
ocated on  
l
eft fue tank  
l
located side CV  
i
n
R
rai viewed  
l
(
from  
c
on rol panel  
t
end)  
adap er bo  
t
x
SHOWN FOR REFERENCE ONLY-  
NOT PART OF CV ADAPTER  
S1 small  
s
witch  
#
RIGH  
T
SIDE OF ENGINE  
OM CONTROL PANEL)  
OUTPUTS  
IN  
P
UT  
CR1 CONTACTO  
DR IVE INPUT  
S
located on face of  
(ASVIEWED  
F
R
CV adap  
ter bo  
x
R
S1  
ALTERNATOR  
65AM 12 OLT  
IDLER ENGINE PROTECTION PC BOARD  
/
AMMET  
DISCHARG  
E
R
SHOW  
HIL  
WITCH  
S
E
F
ULL  
Ac  
J
1-8  
LOCATED BEHIND  
LEFT SIDE OF ENGINE  
(ASVIEWED OM CONTROL PANEL)  
F
UEL  
F
I
LTER,  
P
/
V
LOCATED BEHIND LOWER PORTION OF CONTROL PANEL  
608  
v
GL  
S
O
WITCH  
W
PLUG  
E
G
W
S
PRESSING  
*140vdc  
610  
F
R
GL  
OW  
PL  
U
vv  
610  
J32-1  
J32-2  
J32-3  
J32-4  
(J1-8 toJ1-4)  
UNUSED  
Y
+15VDC  
+
140VDC  
59  
TYPI  
J31-3  
53  
D+  
510  
140vdc (w/  
rheo-  
statat ax)  
m
IDL  
OLENOI  
ULL OIL  
E
140vdc  
(J2-3 toJ1-4)  
500 OHMS  
W
P. C.  
SCHEMATI  
B
D. L12400-2  
G4828-2  
510  
USE  
D
FO  
R
Y
T
M
OROI  
ACHINES  
D
I
N
AC  
B
+
C
H
P
AL CURRENT DR AW:  
GL  
O
W
PLUGS  
CR1 CONTACTO  
DRIVE CIRCUIT  
R
C
C
L
R1  
OI  
4
S
P
D
J
2-  
3
POWER  
SUPPLY  
50  
50B  
C
AUXILIAR  
R
OL  
ULL  
212E  
D
C
OIL  
-
-
1.1A  
46A  
TYPI  
CAL  
J
1-  
3
C
CENTER OF CONTROL PANEL  
RE ENGINE  
PROT CTION  
LIGHT  
12 OLT NORMALLY OFF  
BOARD  
POWER  
606  
23-24vdc  
nCV  
605  
25  
ocated  
CV adap er bo  
COIL  
CURRENT DR AW  
2
FLYBACK  
DIODE  
B3  
55  
no  
-40 TO 40 AMPS  
AMMETER  
D
CR1  
CV adap  
l
ocated side  
i
n
600  
TO D1AC  
POST  
U
IS 40 +/-  
3
AMPS  
H
OL OIL  
D
C
IGNITION  
WITCH  
203  
t
er box  
E
ENGINE  
SHUTDOWN  
61  
J31-  
4
i
25V  
57  
*0vdc  
J31-8  
J31-2  
J31-1  
51  
S
ST  
ART SWITCH  
1
J
1-  
7
2 AMP  
+
-
N.C.  
(J2-2 toJ1-4)  
B
D2  
-
no  
no  
P
OLARITY  
SWITCH  
J
2-  
2
212C  
56  
SHOW  
"OFF" POSITION  
50A  
51A  
V
-
500  
613  
35A  
600  
A
360-440 OHMS  
CR1  
@
C
10A  
B5  
N
IN  
+
3
TO P8-2  
E
XC. OVER-  
VOLTAG  
PROTECTION  
212D  
212F  
800V  
CR1  
n.c.  
(NO AFFEC  
T
W/ CV  
C
LOCATED ABOVE ENGINE  
RI  
G
HT SI  
D
E
OF  
E
RIGH SIDE OF ENGINE BY  
T
l
in  
side  
C
R1  
CONTACT  
TO  
PC  
BD  
ADAPTER HOOKED UP)  
A
LTERNATOR.  
229  
CR1 CONTACTO  
R
N.O.  
INJECTION PUMP  
INJ CTI UM  
OLENOI  
ENGI  
N
E
(
AS  
OM  
OL PANEL)  
t
x
CR1  
B
235  
S
J1-10  
ENGINE  
RUNNING  
RIGH  
T
SIDE OF ENGINE  
FR  
J31-9  
212A  
I
DR IVE R E TUR N  
J
1-  
4
58  
58H  
E
O
N
P
P
VIEWE  
D
FR  
5
B
_
(ASVIEWED  
OM CONTROL PANEL)  
ST  
S
ARTER  
612  
611  
238  
TEMPERATURE  
GAUGE  
600  
667  
W
+
G
602  
S
S
D
CONT  
R
+
140VDC  
TYPI  
C
AL CURRENT DRAW:  
OLENOID  
J31-6  
43  
POWER OUTPUT  
TO SHUNT  
ARC  
44  
HOUR  
ENGINE  
PROT CTION  
3.3A  
VOLTAGE  
METER  
LOWER  
P
ANEL  
APPROXIMAT  
E
RESISTANCE:  
+
W
G
+
J
1-1  
G
FIELD  
J
2-6  
FEEDBACK  
GENERATOR  
+15VDC  
E
12  
ATTERY  
212Blocated genera  
or  
V
OLT  
GND  
S
CREW  
3.3 HM  
O
S
509  
TEMPERATUR  
E
S
WITC  
H
/SENDER  
SHUNT FIEL  
D
W
AND  
ALTERNATOR  
B
E
N
GINE  
located engine right side  
view fro on rol pane end)  
c
v
*S E E WAVE FORM  
(J2-6 toJ2-1)  
RIGH  
T
SIDE OF ENGINE BY  
+
15VDC  
t
machine  
STARTE  
R
(
m
c
t
l
fl
ywheel  
diode  
SENDE  
R
OPE  
RATION:  
UPPER ANEL  
P
SWITC  
H
C
LOSES  
PWM  
vv  
S1 small  
located on faceof  
CV adap  
FUEFL  
PUMP  
AT 230v  
+/-6vF  
OIL  
ILLER  
74hz  
endof  
SENDE  
FLA  
EL  
(S  
FO  
S
Y
B
L
HING  
TIMER  
140  
194  
212  
v
F
-
-
-
>
>
>
134+/-13.5 OHMS  
GND SCREW  
s
witch  
1A  
1000  
TYPI  
C
AL CURRENT DRAW:  
FLYWHEEL  
DIODE  
*12.9vdc  
v
F
51.2+/-4.3 OHMS  
vv  
D
A
E
R
S1C  
V
R
IS APPROX.  
S1  
D
(J1-5 toJ1-2)  
77  
3A  
J
2-5  
t
er box  
APPROXIMAT  
E
RESISTANCE:  
v
F
38.5+/-  
3
OHMS  
J
1-  
1-  
1-  
5
E
ELOW  
GIC)  
FRAME  
500 OHMS AT 70vF FRAME  
503  
S1 small  
s
witch  
R
B
c
v
m
ax  
3-4  
O
HM  
S
O
ENGINE BLOCK  
10  
located on face of  
CV adap er bo  
R3  
35  
A
J
2-  
1
J
6
120 OHMS  
2.5W  
CV  
V
OLTAGE  
OL  
OT  
S
-
I
76  
+
567  
501  
CV SWITCH  
t
x
800V  
238A  
J31-1  
0
CENTER OF CONTROL  
PANEL  
K
200  
cw  
J31-7  
54  
30OHMS  
100W  
CONT  
R
J
9
OIL PRESSURE  
GAUGE  
F
OR  
SHUN  
DRIVE CIRCUIT  
T
FIELD  
75  
*3. 1vdc  
(J1-9 toJ1-2)  
WK  
G
P
G
SHUNT  
FIELD  
located on face of  
CV adap er bo  
HOUR  
METER  
D1  
J31-5  
t
x
B
OIL PRESSUR  
LEFT SIDE OF ENGINE  
(ASVIEWED OM CONTROL PANEL)  
E
S
WITCH  
/SENDER  
Q2  
201  
S1  
+
FR  
WE LD COMMON  
1/8 AMP  
IDLE  
R
DEL  
AY  
TIME  
R
CIR  
UITS  
J
1-  
2
Bc  
ALTERNATOR  
OTOR  
521  
Q2  
O
N
F
O
R
HI  
G
H
I
DL  
E
v
SENDE  
SI  
40PSI  
80 SI  
R
>
>
OPERATI  
10+/-5 HM  
105+/-5 HM  
187+/-5 HM  
R
vv  
S
WIT  
6
C
H
OPENS  
PSI  
B2  
B1  
0
P
-
-
O
O
AT +/-2  
S1 small  
located on faceof  
CV adap er bo  
s
witch  
S2  
SHOW  
IDLE  
N
I
N
"AUT  
O
P
-
>
*NOT  
ODE  
128m  
E
:
m
ea  
s
uremen  
t
m
ad  
e
i
nCV ode.  
m
t
x
S2  
l
arge  
s
witch  
l
ocated on  
"
POSITION  
TO REEDRELAY  
844  
844A  
faceof CVadap  
t
er bo  
x
C
V
ADAPTER  
R
IDL  
E
R
SWITCH  
V
OLTAG  
E
WAVEF  
O
RM  
:
J2-6 to J2-  
1
IN  
C
V
M
CONT OL PCB  
POSITIVE  
positive stud ocated on  
right fue an rai viewed  
ro on rol pane end)  
l
k
12  
.
8m  
s
.
s
621  
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
l
t
t
l
(
l
25,000uf  
75v  
50-250v  
50-250  
v
f
m
c
x4  
5.2ms  
.
5m  
s
LE  
B-BLAC  
G-GREEN  
O-ORANGE  
R-RE PINK  
U-BLUE  
W- HIT  
A
D
C
OL  
O
R
CODE:  
C
OMPONENT  
CAPACIT R: MFD/  
RESIST R: HMS/  
V
AL  
U
E
U
NITS:  
OLT  
ATT  
666  
R1  
0v  
0v  
ENGI  
N
E
PROT  
E
CTI  
O
N
AN  
D
ALTERNAT  
O
R
FLASHI  
N
G
D
EL  
A
Y
TIME  
R
L
OGI  
C
IDL  
E
S
OLENOID CIRCUIT  
L
O
GIC  
J
2
K
O
R
GRAY  
O
V
S
MAX  
POT/NO  
L
OAD  
MIN POT/NO LOAD  
O
O
W
S
UPO  
N
RECIEVEI  
ENGI PROT  
CIRCUIT  
TIM EL  
NG  
POWER, CIRCUIT  
CTI BYPASSED. AFT  
CLOSE AN ENGI PORECTI  
WHE ENGI PROT CTI ENABL  
OIL PRESSUR WILL AN  
OF ENGI PROT N CIRCUIT.  
T
O
FLAS  
H
E
ALTERNAT  
R
O
A
R
I
S
OPENED  
Y, ALTERNATOR  
ENABL D. OTE:  
D, IF ENGINE  
ACHI WILL  
1.  
W
HE ENGI RUNNI  
N
T
H
E
NE  
I
S
N
G
I
N HI  
G
H
IDL  
E
O
R
UNDE  
R
L
OAD,  
T
H
E
S
OLENOI  
D
I
S
N
OT ENERGIZED.  
C1  
C2  
C3  
C4  
-
+
-
AN  
D
N
E
E
I
ON  
IS  
TIM EL  
E
O
D
N
622  
100 OHMS  
50  
D
O
R
FLA  
S
E
HI  
R
N
G
S
D
D
E
N
E
E
I
S
E
N
2. IF  
PE  
E-ENERGIZ  
N
O
AUXILIAR  
Y
CURRENT DR A  
ULL AN OL  
ALF SECOND.  
W
O
R
W
EL  
D
L
T
OA  
HE  
D
I
I
S
SENSE  
D
FO  
R
D
15 SECOND  
S
AN  
D
D.  
T
H
TH  
E
E
I
DL  
E
R
S
WIT  
CH  
IS  
IS  
CONNECT  
OR  
PIN  
NUMBERS:  
C
ap  
resistor  
adap er bo  
a
ci  
t
or bank an bleeder  
d
l
ocated side CV  
in  
W
AFT  
E
D
A
Y
T
N
N
ON  
I
S
E
TH  
E
N
O
N
(
A
UTO),  
T
H
E
P
D
H
D
C
OIL OF  
DL  
E
R
S
OLENOI  
AR ENERGIZ  
E
E
P
ULL  
C
OIL  
EX. 12PIN CONNECTO  
R
W
E
t
x
CV MODE  
–
POWER UP SEQUENCE  
VV MODE  
–
POWER UP SEQUENC  
E
IS  
NOT ST  
A
N
RT  
BECAUS  
E
D
HE  
E
N
B
E
L
O
W
D
T
H
E
M
E
D
E
D
AFT  
E
R
H
A
+
GENERATOR  
Y-YELLOW  
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  
1
7
2
SHUT DOW  
E
THE  
E
ECTIO  
6
Exciter rotor is flashed from 12v battery supply at  
LABELS  
:
3. IF AN AUXILIARY CURRENT  
THE IDLE SOLENOID IS DE-ENERGIZED.  
DRA  
W
OR  
W
ELD LOAD IS SENSED OR THE IDLER WITCH IS CLOSED (HIGH),  
S
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.  
C
OMMON  
FRAM  
GROUND  
drive circuit on PC board at J1 pins  
4
&
8.  
12  
E
CR1 closes, applying power to PC board at J2 pins  
and disconnecting flashing circuit.  
PC Board PWM circuit regulates output voltage by  
using voltage feedback from J1 pin and control pot  
at J1 pin to control current thru the shunt fields.  
Note!!: Rheostat ust be set to max for CV operation.  
2
LATCH  
R ON PC BOARD  
VV negstud  
right fue an  
viewed ro  
pane end)  
l
ocated on  
rai  
on  
&
3
EARTH  
l
f
t
k
l
t
CV negstud  
adap er bo  
ue an rai  
on rol pane  
l
ocated on  
ounted on  
viewed ro  
end)  
VIEW OF CONNECTO  
GROUND  
(
m
c
rol  
t
x
m
left  
C
V
VV  
l
1
f
l
t
k
l
(
l
f
m
THIS DOCUMENT CONTAINS PROPRIETAR  
Y
INFORMATION OWNED  
B
Y
LINCOLN GLOBAL, INC. AND MA NOT BE DUPLICATED, COMMUNICATED  
Y
NEG.  
NEG.  
c
t
6
PROPRIETARY & CONFIDENTIAL:  
TO  
O
THER PARTIES OR USED FOR AN  
Y
PURPOS WITHOU  
E
T
THE EXPRES WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.  
S
M
CV WELD OUTPUT  
MIN TO MAX OCV 8-41vdc  
MANUFACTURING TO  
L
ERANCE  
P
ER E2056  
CONTROL: CLEVE  
DRAWN BY:  
Maglietta  
L
AND  
SCA  
L
E:  
UNLESS OTHERWISE SPECIFIED TOLERANCE:  
N
OT  
E
!!  
:
WHEN INSTALLING CV ADAPTER,  
NEGATI  
POSITIVE"  
EQUIP  
M
ENT TYPE:  
1
1
DOCUMEN  
SAE-400  
PAGE ___ OF ___  
T
ON  
ON  
ON  
2
3
PLACE  
D
ECIMAL  
S
IS  
.02 in.  
(
0.5 mm)  
NONE  
"ELECTRODE" STUD BECOMES VV  
"
VE"  
WELD RANGE  
MAX LOAD  
15-35vdc  
PLACE  
D
E
CIMALS IS  
.
00  
A
2
i
n.  
(
0.  
0
5
mm)  
T
DOCUMEN  
NUMBER:  
IF PRIN  
T
ED  
STUD,& "TO WORK" STUD BECOMES  
STUD.  
"
A
LL ANGL  
E
S
I
S
.5 OF  
D
E
GREE  
SUBJECT:  
REVISION:  
400A  
500A  
@
@
35V  
35V  
@
@
60% D.C.  
35% D.C.  
MACHINE SCHEMATIC  
PROJEC  
NUMBER:  
@
A
1
SIZE  
MATERI  
WITH  
A
L
TO  
L
ERANC  
E
("  
"
)
TO  
AGREE  
ENGINEER:  
APPROVED:  
D.  
B
ENDER  
-
t
UNIITNSC: H  
LISHED  
E
ANDARD  
REFERENCE:  
-
DO NOPTUBSCAL  
STTHIS DRS.AWING  
MATERIAL  
DISPOSI ION:  
APPROVA  
L
T
G4924  
NA  
1/1/2000  
D
CRM38346  
T
DATE:  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
®
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-9  
G-9  
ELECTRICAL DIAGRAMS  
SCHEMATIC - COMPLETE MACHINE - CODE 11408 (G5827)  
7
8 2 G 5  
ENGI  
N
EERING CONTROLLE  
D
CHANGE  
DETAIL:  
Revised  
P
S
OL  
WITCH  
ARITY  
MANUFACTURER: No  
(SHOWNIN POSITI  
R
VE  
POISTION)  
TO D1  
AC  
POST  
GENERATOR SHUNT  
FIELDCIRCUIT  
4
AUXILIARY POWER  
CIRCUIT  
2
TO D1  
AC POSTS  
35  
800V  
A
N
U
215  
214  
203  
located behind uppe  
r
500 OHMS  
50W  
1
c
on rol pane on reactor bo  
t
l
x
+
-
D2  
B
3
REMOT  
E
AUXILIARY OUTPUT  
ROTOR FIELDAND  
FLASH CIRCUIT  
located behind uppe  
r
RECEPTACLE  
AND PLUG  
located ower enter  
l
c
OCV  
115/230 VAC  
+
10%  
@
1800RPM  
cont  
rol pane  
l
on  
CENTER OFF =NO WELD OUTPUT  
of con rol panel  
t
EXCITER  
602C  
DING  
actor bo  
x
203A  
ren.c  
MAX LOAD  
3KW  
@
100% D.C.  
t
op ht of  
GENEriogRrAraTO  
X
B
-TERMINAL  
WI  
N
gene  
t
f
me  
raR  
X
n.c.  
.
diodes  
l
ocated behind  
al  
t
erna  
t
or  
&
rotor  
l
ocated at endof genera  
tor  
LEAD  
BLOCK  
G-TERMINA  
uppercon  
t
rol pane  
l
BRUS  
VIEWE  
H
POSITI  
O
N
SHOW  
N
AS  
600A  
810  
L
41  
R
D
F
R
OMCONTR  
OL PANEL  
G
ANEL  
CREW  
G
G
A
P8-2  
600  
UPPER  
GND  
P
ANEL  
ALTERNATOR  
OTOR  
+/- 1. 0 @ 25  
UPPER  
P
64ohms +/- 6.4  
150 W  
S
CREW  
R
m
GND  
S
E
F
A
&
RMATURE  
BRUSHES  
41.5 oh  
s
C
cc  
w
2
Y-TERMINAL  
AUXILIARY  
WI DINGS  
Y
U
-
R
N
202  
max  
MI  
MAX rheo  
N
rheo  
=
54vdc  
140vdc  
R
R
140vdc  
=
SERI  
E
S
FIELD  
-
D1  
n.c  
.
25OHM  
50  
x3  
820  
N
N
A
1
-
W
-TERMINA  
W
W
+
SHUNT  
FIEL  
382-40.6 ohms  
25  
LO  
C
AL  
WITCH  
OCAL  
/
REMOTE  
L
D
35  
A
N
S
S
N
S
W
W
W
.
800V  
(SHOWN IN  
POSITION)  
L
201A  
CURRENT  
SENSE  
TO OI  
@
C
located behind uppe  
r
-
+
42  
+
20A  
20A  
c
ontrol panel on  
OPTIONAL REMOTE  
CONTROL BOX  
115 DUPLE X  
V
P
OLES  
R
D
reactor box  
located middle  
lower  
602  
P8-4 MI  
C
B3  
RECEPTACLE  
W
G
of con rol panel  
t
P8-3  
B
B
B
201  
11B  
11  
N
rheo  
=
86vac  
42  
A
WE LDING  
GENERATOR  
MAX rheo=0vac  
S
N
S
N
B
located upperLt  
hand side behind  
CB2  
B
400F  
ANEL  
CREW  
JOon  
EL  
HE+O/-S6T.4A, T  
B
c
trol panel  
UPPER  
GND  
P
602  
A
UPPER  
P
ANE L  
TO  
PC  
BD  
max  
S
G
GND  
S
CREW  
844-TERMINA  
L
S
ECTOR  
VARI  
A
BL  
E
cc  
w
15A  
11A  
B
120 OHMS  
2.5W  
WINDING SPEC'S & RESISTANCES  
EXCITER  
2
CR  
R
REACTOR  
64  
W
o
hms 15  
0
located behind uppe  
on rol pane on  
reactor bo  
r
CB1  
WE LD CIR CUIT  
REEeDdREhLiAY  
located upperRt  
hand side behind  
6A  
c
t
l
TO D1  
locat be nd  
B
602  
B
x
LOWER  
GND  
P
ANEL  
w
orkstud  
A
C
POST  
WINDING  
POWER  
QUADRATURE  
SPEC  
RESISTANCE  
control panel  
15A  
U
1A  
S
CREW  
ALT-214-3C .230 OHMS  
ALT-214-3B .560 OHMS  
@
@
@
25C  
25C  
25C  
1000V  
7A  
G
R
B
B
AUXILIARY (TAIL) ALT-214-3D .424 OHMS  
230 DUPLE X  
V
ROTOR (4-POLE) ALT-214-3A 41.4+/-1.0 OHMS  
@
25C  
UPPER  
GND  
P
ANEL  
RECEPTACLE  
DIAGRAM  
M14262  
238  
ou  
rai  
(electrode closest to con  
t
putstud  
s
l
ocated on right fue  
ro on rol pane end)  
rol panel)  
l
tank  
S
CREW  
WOR  
K
EL  
E
CTROD  
E
l
(
viewed  
f
m
c
t
l
GENERATOR  
t
INTERPOLE  
SHUNT FIELD  
SERIES FIELD  
ARMATURE  
DIAGRAM  
S12261-25 N/A  
FKL-5AJ  
19.1-20.3 OHMS  
@
25C  
CC WELD OUTPUT  
1800 RPM  
80-575 AMPS  
400A 40V 100% D.C. (1725 RPM)  
TO HOUR  
ETER (+)  
MAY NOT APPEAR ON ALL MODELS  
FKL-420-U N/A  
FKL-37.4N N/A  
M5570  
MIN TO MAX OCV 57-97VDC  
@
M
WELD RANGE  
MAX LOAD  
ENGINE  
TEMPERATURE  
SENSOR  
RI  
G
HT SI  
D
E
OF ENGINE  
UM  
@
@
INJ  
TIMIN  
E
CTI  
O
N
P
UM  
P
ON  
I
NJ CTI  
E
O
N
P
P
G
S
OLENOID  
INJ  
E
CTI  
O
N
P
TY  
UM  
P
TIMING  
P. CURRENT  
APPROX.  
16 HM  
212F  
S
OLENOI  
D
0.9A  
DRA  
RESISTANC  
W
SAE400  
OPTIONAL CV ADAPTER  
INTERFACE WITH  
16  
0.9 AMPS  
O
HM  
S
602  
E
O
S
C
V
ADAPTER  
CONT OL PCB  
(SCHEM. L6922)  
CV adap  
t
er bo  
x
l
ocated on  
l
eft fue tank  
l
located side CV  
i
n
R
rai viewed  
l
(
fro  
m
c
on rol panel  
t
end)  
adap er bo  
t
x
SHOWN FOR REFERENCE ONLY-  
NOT PART OF CV ADAPTER  
S1 small  
s
witch  
#
O
UT  
P
UT  
S
IN  
P
UT  
CR1 CONTACTO  
DR IVE INPUT  
S
located on face of  
AMMET  
DISCHARG  
GL PL  
E
R
SHOW  
HIL  
WITCH  
S
E
F
ULL  
CV adap  
ter bo  
x
RI  
G
HT SI  
D
E
OF ENGI  
N
E
(
A
S
VIEWED  
R
S1  
E
G
W
S
PRESSING  
IDLER ENGINE PROTECTION PC BOARD  
/
FROM CONT  
ROL PANEL)  
Ac  
J
1-8  
OW  
U
LO  
C
AT  
E
D
BEHI OWE PORTI OF CONT OL PANEL  
N
D
L
R
O
N
R
608  
v
GL  
S
O
WITCH  
W
PLUG  
ALTERNATOR  
65AM 12 OLT  
*140vdc  
610  
Y
vv  
610  
J32-1  
J32-2  
J32-3  
J32-4  
P
/
V
(J1-8 toJ1-4)  
GL  
OW  
PLUGS  
UNUSED  
USE  
+15VDC  
+
140VDC  
59  
J31-3  
B3  
53  
TYPI  
CURRENT  
DRA  
D+  
510  
140vdc (w  
/
rheo-  
statat  
m
ax)  
IDL  
OLENOI  
ULL OIL  
E
140vdc  
(J2-3 toJ1-4)  
CAL  
500 OHMS  
50  
P. C.  
SCHEMATI  
B
D. L12400-2  
G4828-2  
510  
D
FO  
R
Y
T
M
OROI  
ACHINES  
D
I
N
AC  
B
+
TYPICAL CURRENT DR AW:  
CR1 CONTACTO  
DRIVE CIRCUIT  
R
C
C
L
R1  
OI  
4
S
P
D
J
2-  
3
POWER  
SUPPLY  
W
50B  
C
AUXILIAR  
R
H
P
OL  
ULL  
212E  
D
COIL  
-
-
1.1A  
46A  
J
1-3  
W
IS  
C
CENT  
E
R
OF CONT  
ENGI PROT  
OLT NORMALL  
R
OL PANEL  
CTI LI  
OFF  
BOARD  
POWER  
606  
23-24vdc  
nCV  
605  
25  
ocated  
CV adap er bo  
COIL  
2
FLYBACK  
DIODE  
55  
57  
-40 TO 40 AMPS  
AMMETER  
40 +/-  
AMPS  
3
no  
RE  
12  
D
NE  
E
ON  
GHT  
CR1  
CV adap  
l
ocated side  
i
n
600  
TO D1AC  
POST  
U
H
OL OIL  
D
C
203  
t
er box  
V
-
Y
ENGINE  
61  
J31-4  
i
25V  
*0vdc  
J31-8  
J31-2  
J31-1  
51  
ST  
ART  
S
WITCH  
1
J
1-7  
2 AMP  
SHUTDOWN  
+
-
N.C.  
R1  
N.O.  
(J2-2 toJ1-4)  
B
D2  
-
no  
no  
P
OLARITY  
SWITCH  
W/ CV  
J
2-  
2
212C  
56  
IGNITION  
WITCH  
51A  
50A  
500  
613  
35  
A
600  
A
360-440 OHMS  
CR1  
@
C
10A  
B5  
RI  
G
HT SI  
NJ CTI  
FUEL SHUTDOW  
AL CURRENT DRAW: 0.9  
D
E
OF ENGINE  
+
3
TO P8-2  
TO  
J1-10  
E
XC. OVER-  
VOLTAG  
PROTECTION  
800V  
C
212D  
212F  
n.c.  
(NO AFFEC  
T
C
E
B
Y
I
E
O
N
P
UM  
P
l
in  
side  
C
R1  
CONTACT  
P
C
BD  
S
ADAPTER HOOKED UP)  
229  
CR1 CONTACTO  
R
t
x
C
R1  
B
235  
S
N
S
OLENOI  
D
SHOW  
"OFF" POSITION  
N
IN  
ENGINE  
J31-9  
212A  
I
DR IVE R E TUR N  
J
1-  
4
58  
58H  
5
B
_
TYPI  
C
A
612  
611  
238  
600  
667  
W
+
G
RUNNING  
602  
S
+
140VDC  
J31-6  
43  
POWER OUTPUT  
TO SHUNT  
ARC  
44  
TEMPERATUR  
HOUR  
TEMPERATURE  
GAUGE  
12 OLT  
APPROXIMAT  
E
RESISTANCE: 16  
O
HM  
S
ENGINE  
VOLTAGE  
METER  
LOWER  
GND  
P
ANEL  
+
W
G
+
J
1-1  
G
FIELD  
J
2-6  
FEEDBACK  
GENERATOR  
+15VDC  
PROT  
AND  
ALTERNATOR  
ECTION  
V
S
CREW  
509  
E
S
WITCH  
/SENDER  
SHUNT FIEL  
D
W
BATTERY  
located genera or  
endof achine  
RI  
ABOV  
FUEL  
TYPI  
APPROXIMAT  
3-4 HM  
CENT  
HOU  
G
HT SI  
D
E
OF ENGINE  
EL FILTER  
UM  
AL CURRENT DR AW:  
RESISTANCE:  
E
N
GINE  
located engine right side  
view fro on rol pane end)  
c
v
*S E E WAVE FORM  
(J2-6 toJ2-1)  
+
15VDC  
t
STAR TE  
R
(
m
c
t
l
fl
ywheel  
diode  
E
F
U
UPPER  
P
ANEL  
CREW  
212B  
ATION:  
SENDE  
R
OPE  
R
74hz  
m
FLA  
EL  
(S  
FO  
S
Y
B
L
HING  
TIMER  
GND  
S
P
P
PWM  
vv  
S1 small  
s
witch  
1A  
1000  
SWITC  
AT 230  
H
C
LOSES  
FLYWHEEL  
DIODE  
140  
194  
212  
v
F
-
-
-
>
>
>
134+/-13.5 OHMS  
51.2+/-4.3 OHMS  
*12.9vdc  
located on faceof  
D
A
E
R
vv  
S1C  
V
C
3A  
SENDE IS APPROX.  
R
v
+/-6vF  
S1  
D
(J1-5 toJ1-2)  
77  
v
F
J
2-5  
CV adapter box  
J
1-  
1-  
1-  
5
E
ELOW  
GIC)  
FRAME  
500 OHMS AT 70vF FRAME  
503  
E
S1 small  
s
witch  
vF  
38.5+/-  
3
OHMS  
R
B
c
v
m
ax  
O
ENGINE BLOCK  
10  
located on face of  
CV adap er bo  
R3  
35  
800V  
A
J
2-1  
O
S
J
6
120 OHMS  
2.5W  
CV  
V
OLTAGE  
OL  
OT  
S
-
I
76  
+
567  
501  
t
x
238A  
J31-10  
J31-5  
K
200  
cw  
J31-7  
54  
30OHMS  
100W  
CONT  
R
E
R
OF CONTROL PANEL  
J
9
CV SWITCH  
F
OR  
12.6  
AT REST  
14-14.5 VOLT  
HIL RUNNING  
V
OLTS MIN  
SHUN  
DRIVE CIRCUIT  
T
FIELD  
75  
*3. 1vdc  
(J1-9 toJ1-2)  
OIL PRESSURE  
GAUGE  
WK  
OIL PRESSUR  
G
/
P
R
M
ETER  
G
SHUNT  
FIELD  
located on face of  
CV adap er bo  
D1  
E
S
WITC  
H
SENDER  
t
x
B
Q2  
S
201  
W
E
S1  
+
SENDE OPERATI  
R
>
>
-
O
S
N:  
WE LD COMMON  
1/8 AMP  
IDL  
E
Q2  
R
D
O
EL  
N
A
FO  
Y
R
TIM  
HIG  
E
R
H
CI  
IDL  
R
E
UIT  
S
J
1-  
2
Bc  
0
P
SI 10+/-5 HM  
40PSI 105+/-5 HM  
80 SI 187+/-5 HM  
-
-
O
O
S
WIT  
6
C
H
OPENS  
PSI  
521  
ALTERNATOR  
OTOR  
v
S
S
AT +/-2  
vv  
R
P
>
O
B2  
B1  
S1 small  
located on faceof  
CV adap er bo  
s
witch  
S2  
SHOW  
N
I
N
"AUT  
O
*NOT  
ODE  
128m  
E
:
m
ea  
s
uremen  
t
m
ad  
e
i
nCV ode.  
m
t
x
S2  
l
arge  
s
witch  
l
ocated on  
IDL  
E
"
POSITION  
TO REEDRELAY  
2C  
844  
844A  
face of CVadap  
t
er bo  
x
R
C
V
ADAPTER  
R
IDLE  
R
SWITCH  
V
OLTAG  
E
WAVEF  
O
RM  
:
J2-6 to J2-  
1
IN  
C
V
M
CONT OL PCB  
POSITIVE  
positive stud ocated on  
right fue an rai viewed  
ro on rol pane end)  
l
k
12  
.
8ms  
.
s
621  
1
2
3
4
5
6
l
t
t
l
(
l
1
2
3
4
5
6
7
8
9
50-250  
v
50-250v  
f
m
c
25,000uf 75v  
x4  
5.2m  
s
.
5m  
s
LE  
B-BLAC  
G-GREEN  
O-ORANGE  
R-RE PINK  
U-BLUE  
W- HIT  
A
D
COL  
O
R
CODE:  
C
OMPONENT  
CAPACIT R: MFD/  
RESIST R: HMS/  
V
AL  
U
E
U
NITS:  
OLT  
ATT  
666  
R1  
0v  
0v  
ENGI  
N
E
PROTE  
CTI  
O
N
AND  
ALTERNAT  
O
R
FLASHI  
N
G
DEL  
A
Y
TIME  
R
L
O
GI  
C
IDLE  
S
OLENOID CIRCUIT  
L
O
GIC  
J
2
K
O
R
GRAY  
O
V
S
MAX  
P
OT/NO  
L
OAD  
MIN POT/NO LOAD  
O
O
W
S
UPO  
N
RECIEVEI  
ENGI PROT  
CIRCUIT  
TIM EL  
N
G
E
POWER, CIRCUIT  
CTI BYPASSED. AFT  
CLOSE AN ENGI PORECTI  
WHE ENGI PROT CTI ENABL  
OIL PRESSUR WILL AN  
OF ENGI PROT N CIRCUIT.  
T
O
FLAS  
H
E
ALTERNAT  
O
A
R
I
S
OPENED  
Y, ALTERNATOR  
ENABL D. OTE:  
D, IF ENGINE  
ACHI WILL  
1.  
W
HE ENGI RUNNI  
N
T
H
E
N
E
I
S
N
G
I
N HIGH  
IDL  
E
OR  
UNDE  
R
L
OAD,  
TH  
E
S
OLENOI  
D
IS  
NOT ENERGIZED.  
C1  
C2  
C3  
C4  
-
+
-
AN  
FLA  
AFT  
D
S
E
NE  
ON  
IS  
R
TIM EL  
E
O
D
N
622  
100 OHMS  
50  
D
OR  
Cap  
a
ci  
t
or bank an  
d
bleede  
r
CONNECT  
OR  
PIN  
N
UMBERS:  
HI  
NG  
IS  
D
D
N
E
E
IS  
E
HE  
N
2. IF  
PE  
E-ENERGIZ  
N
O
AUXILIAR  
Y
CURRENT DR A  
ULL AN OL  
ALF SECOND.  
W
O
R
W
EL  
D
L
OA  
D
IS  
SENSE  
D
F
O
R
15 SECOND  
S
AN  
D
T
H
E
I
DL  
E
R
S
WIT  
C
S
H
IS  
resistor  
l
ocated side CV  
in  
W
R
E
D
AY  
N
N
E
O
N
O
I
W
S
E
T
O
N
(
A
UTO),  
T
H
E
P
D
H
D
C
OIL OF  
T
HE  
I
DL  
E
R
S
OLENOI  
D
AR  
E
ENERGIZ  
E
D.  
T
H
E
P
ULL  
C
OIL  
I
EX. 12PIN CONNECTO  
R
adapter bo  
x
W
E
CV MODE  
–
POWER UP SEQUENCE  
VV MODE  
–
POWER UP SEQUENC  
E
IS  
NOT ST  
A
N
RT  
BECAUS  
E
D
T
H
E
E
B
E
L
D
TH  
E
M
NE  
D
E
D
AFT  
E
R
H
A
+
GENERATOR  
Y-YELLOW  
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  
1
7
2
SHUT DOW  
E
T
HE  
NE  
ECTIO  
6
Exciter rotor is flashed from 12v battery supply at  
LABELS  
:
3. IF AN AUXILIARY CURRENT  
DRA  
W
OR  
W
ELD LOAD IS SENSED OR THE IDLER WITCH IS CLOSED (HIGH),  
S
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.  
THE IDLE SOLENOID IS DE-ENERGIZED.  
C
OMMON  
FRAM  
GROUND  
drive circuit on PC board at J1 pins  
4
&
8.  
12  
E
CR1 closes, applying power to PC board at J2 pins  
and disconnecting flashing circuit.  
PC Board PWM circuit regulates output voltage by  
using voltage feedback from J1 pin and control pot  
at J1 pin to control current thru the shunt fields.  
Note!!: Rheostat ust be set to max for CV operation.  
2
LATCH  
R ON PC BOARD  
VV negstud  
right fue an  
viewed ro  
pane end)  
l
ocated on  
rai  
on  
&
3
EARTH  
l
f
t
k
l
t
CV negstud  
adap er bo  
ue an rai  
on rol pane  
l
ocated on  
ounted on  
viewed ro  
end)  
VIEW OF CONNECTO  
GROUND  
(
m
c
rol  
t
t
t
x
l
m
left  
m
C
V
VV  
l
1
f
c
l
k
(
l
f
THIS DOCUMENT CONTAINS PROPRIETAR  
Y
INFORMATION OWNED  
B
Y
LINCOLN GLOBAL, INC. AND MA NOT BE DUPLICATED, COMMUNICATED  
Y
NEG.  
NEG.  
6
PROPRIETARY & CONFIDENTIAL:  
TO  
AND  
O
THER PARTIES OR USED FOR AN  
Y
PURPOS WITHOU  
E
T
THE EXPRES WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.  
S
M
CV WELD OUTPUT  
MIN TO MAX OCV 8-41vdc  
M
ANUFACTURING TO  
L
ERANC  
E
P
ER E2056  
CONTROL: CLEVE  
DRAWN BY:  
Maglietta  
L
SCA  
L
E:  
UNLESS OTHERWISE SPECIFIED TOLERANCE:  
N
OT  
E
!!  
:
WHEN INSTALLING CV ADAPTER,  
NEGATI  
POSITIVE"  
EQUIP  
M
ENT TYPE:  
1
1
DOCUMEN  
SAE-400  
PAGE ___ OF ___  
T
ON  
ON  
ON  
2
3
PLAC  
E
D
ECIMAL  
S
I
S
.02 in.  
(
0.5 mm)  
NONE  
"ELECTRODE" STUD BECOMES VV  
"
VE"  
WELD RANGE  
MAX LOAD  
15-35vdc  
PLACE  
D
E
CIMALS IS  
.
00  
A
2
i
n.  
(
0.  
0
5
mm)  
T
DOCUMEN  
NUMBER:  
IF PRIN  
T
ED  
STUD,& "TO WORK" STUD BECOMES  
STUD.  
"
A
LL ANGL  
E
S
I
S
.5 OF  
D
E
GREE  
SUBJECT:  
REVISION:  
400A  
500A  
@
@
35V  
35V  
@
@
60% D.C.  
35% D.C.  
MACHINE SCHEMATIC  
PROJEC  
NUMBER:  
@
A
1
SIZE  
MATERI  
WITH  
A
L
TO  
L
ERANC  
E
("  
"
)
TO  
A
GREE  
ENGINEER:  
APPROVED:  
D.  
B
ENDER  
-
t
UNIITNSC: H  
LISHED  
ANDARD  
REFERENCE:  
-
DO NOPTUBSCAL  
E
STTHIS DRS.AWING  
MATERIAL  
DISPOSI ION:  
APPROVA  
L
T
G5827  
NA  
1/1/2000  
B
CRM38346  
T
DATE:  
Insight  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
®
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-10  
PC BOARD ASSEMBLY - IDLER/ENGINE SHUTDOWN PC BOARD - CODE 10856 (L11007-2)  
G-10  
ELECTRICAL DIAGRAMS  
2
0 0 1 7 1 - L  
CHANGE DETAIL: TP1, ADDED "K" TOPART NO.  
ENGINEERING CONTROL  
L
ED  
ITEM  
R
EQ'D  
IDENTIFI  
TERMINA  
.047/100  
CATION  
PART NO.  
MANUFACTURER: No  
B1  
C1  
C2,C4,C  
C3  
C8  
C1  
C1  
C1  
D1,D  
D2  
D5,D7  
DZ1  
1
1
7
1
1
1
2
1
3
1
2
1
2
1
1
1
1
2
1
1
4
1
2
T13157-1  
4
TA  
B
L
N
.B.  
S13490-102  
S16668-5  
5
,C6,C  
7
,C9,C16  
.
022/50  
S13490-4  
S13490-3  
9
9
.47/50  
0
S13490-4  
16668-1  
.022/200  
.1/50  
1,C1  
9
S
S
1
3
13490-15  
3,D4  
T12705-3  
T12705-4  
T12199-1  
4
1N4936  
8A/400V  
1N4004  
1N5347B  
1N4744A  
HEADER  
HEADER  
2N4401  
5
T
12702-3  
3
DZ2,DZ4  
T12702-2  
9
J
J
1
2
S18248-1  
S18248-4  
0
N
.B.,N.C.  
N
.B.,N.C.  
Q
Q
Q
Q
1
2
4
5
T12704-6  
T12704-6  
8
1
18  
A,100V,PNP  
HE FET ON H.S  
13.7 1/4W  
A
200V MOSFET (SS)  
N
.A.  
1
,Q  
6
T12704-3  
S18395-3  
7
4
3
X
.
.04  
R1  
R2,R9,R10,R1  
R3  
R4,R2  
R5,R2  
R6  
S19400-1372  
S19400-1500  
S19400-1000  
S19400-3322  
K
2.75  
5
1
150 1/4W  
100 1/4W  
X2  
X3  
2.350  
.750  
X7  
6
4
33.2  
4.75K  
1.5 1/4W  
162 1/4W  
2.0 1/4W  
K
1/4W  
R26  
R22  
R34  
,R2  
5
3
S19400-4751  
Q5  
C3  
R44  
R45  
X4  
X5  
C10  
X1  
1
S19400-1501  
S19400-1620  
S19400-2001  
S19400-6191  
S19400-4752  
K
DZ1  
1.625  
R17  
R32  
R7  
R8  
1
1
4
1
3
1
1
1
1
1
1
5
1
1
2
3
1
2
2
2
1
1
1
1
1
2
1
2
1
R35  
C8  
K
C19  
TP1  
Q4  
R1  
R1  
R1  
R1  
R1  
R1  
R1  
R2  
R2  
R2  
R2  
R3  
R3  
R3  
R3  
R3  
R3  
R3  
R4  
R4  
R4  
R5  
TP  
2
3
4
5
6
7
9
1
2
3
7
0
1
2
4
5
6
9
0
3
6
5
1
,R1  
8
4
,R3  
,R4  
8
5
,R5  
,R4  
6
1
6.19  
K
K
1/4W  
1/4W  
47.5  
Q1  
R14  
C13  
C1  
Q6  
Q2  
L11007-2  
,R4  
T14648-2  
4
0.5 5W  
D2  
S19400-1333  
S19400-2672  
T14648-2  
S19400-2671  
S19400-2213  
S19400-1822  
19400-1002  
19400-6812  
19400-3321  
S19400-68R1  
19400-1001  
18380-1  
S19400-2212  
S19400-1003  
S19400-1821  
S19400-1211  
S19400-7681  
S19400-2002  
S19400-5622  
133  
26.7  
25 5W  
K
K
1/4W  
1/4W  
B1  
R
J1  
J2  
R58  
IDLER ENGINE SHUTDOWN  
2.67  
K
1/4W  
1/4W  
1/4W  
0
221K  
18.2  
K
0
,R2  
8
,R2  
,R4  
9
7
,R4  
8
S
S
S
10  
68.1  
3.32  
K
1/4W  
5.200  
.250  
2.600  
K
K
1/4W  
1/4W  
8.750  
,R3  
,R3  
3
7
68.1 1/4W  
1/4W  
THERMISTOR,PTC,56 OHM  
9.00.0  
S
S
1K  
4
S
,R5  
,R4  
,R5  
8
2
7
22.1  
K
1/4W  
1/4W  
1/4W  
1/4W  
1/4W  
100K  
1.82  
1.21  
7.68  
K
K
K
N.D.  
.050  
20  
56.2  
5J  
K
1/4W  
1/4W  
.225  
K
.100 +.0  
T13640-1  
S15018-1  
5
3
K
1
25  
-.01  
0
X1,X2  
X3  
X4,X7  
X5  
16  
14  
14  
P
P
P
IN I.C. (SS)  
IN I.C. (SS)  
IN QUAD COMPARATOR  
N
.A.  
.A.  
S15018-1  
S15128-1  
15128-1  
5
1
0
N
.025  
YP  
S
IC,431,VOLTAGE REF.  
.075  
T
.
SCHEMATIC REFERENCE: L11006-2C1  
C
R
APACITORS = MFD/VOLTS  
ESISTOR HMS  
N.D.  
CAUTION:  
S
=
O
N
.A.  
THIS  
D
EVI  
C
E IS SUBJ  
E
CT TO DAMAGE BY STATIC  
HANDLI G.  
ELE  
CTRICITY. SEE E2454 BEFOR  
E
N
R
EQ'D  
D
ESCRIP  
PC. BOARD BLANK  
PLASTIC PA SION NUT  
ELECTRICAL INSULATIN  
EPOXY NCAPS LATIN  
TION  
I
TEM  
PART NO.  
N
.B.  
N.C  
N.D  
D
O
N
OT C  
O
AT WITH ENCAPSULATION MATERIAL.  
6 BEFORE ENCAPSULATING.  
ENCAPSULATE WITH ITEM 7 TO DIMENSIONS SHOWN  
1
5
L11007-C  
S14020-5  
1
5
6
7
.
APPLY ITE  
M
E
X
N
.
.004  
lb.  
E353  
E252  
9
7
G
COMPOUND  
ESI  
EXCEPT IN AREA INDICATED WHERE THE  
RE  
MUST BE  
200 gr.  
E
U
G
R
N
NO  
ENCAPSULATION MATERIAL.  
FOR PART  
INCLUDE CL011800(U  
AN S24586PRINT  
S
O
RDERS  
ONLY:  
-
18-2-133-133)  
D
HIS DOCUME  
N
T CONTAINS P  
R
OPRIETARY INFORMATIO  
N
OWNED BY LIN  
C
OLN GLOBAL, INC. A  
N
D MAY NOT BE  
D
UPLICATED,  
C
OMMUNICATED  
PROPRIETARY & CONFIDENTIAL:TTO OT  
M
AKE PER E191  
1
HER PA  
R
TIES O USE  
R
D
FOR ANY  
P
U
RPOSE WITHOUT THE E  
X
PRESS  
W
RITTEN PERMISSIO  
N
OF LINC  
OLN GLOBAL, INC.  
U
NLESS OTHERWISE SPE  
C
IFIE TOLERANCE  
DESIGN INFORM  
TOLERANCE PER E2056  
D
A
TION  
REFERENCE:  
MANUFACTURIN  
G
EQUIPMENT TYPE  
:
1
1
ENGINE WELDERS  
PAGE ___ OF ___  
TES PE E3809-I  
T
R
ON  
2
3
PLACE DECIMALS IS .02  
DRAWN  
B
Y:  
SWB  
-
ON  
PLAC  
E
D
E
CIMAL  
S
I
S
.002  
DEGREE  
DOCUMENT  
DOCUMENT  
REVISION:  
ON ALL ANGLE  
S
IS .5 OF  
A
SUBJECT:  
IDLER/ENGINE SHUTDOWN P.C. BOARD  
UMBER:  
N L11007-2  
MATERIA  
L
TOLERANCE ("  
t
") TO AGREE  
E
NGINEER:  
SCA  
L
E:  
WITH  
MAT E R I AL  
UF  
APPROVAL  
07/15/2002  
DATE :  
PROJECT  
NUMBER:  
B
CRM2211  
5
-D  
T
APPROVED:  
-
1:1  
DO  
N
OPTUSBLCISAHLEED STANDARDS.  
DRAWING  
THIS  
DISPOSITION:  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
®
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-11  
G-11  
ELECTRICAL DIAGRAMS  
SCHEMATIC - IDLER/ENGINE SHUTDOWN PC BOARD - CODE 10856 (L11006-2)  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
®
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-12  
G-12  
ELECTRICAL DIAGRAMS  
PC BOARD ASSEMBLY - IDLER/ENGINE SHUTDOWN PC BOARD (L12400-2)  
2
4 0 1 0 2 - L  
ITEM (USED WITH)*  
QTY PART NUMBER  
DESCRIPTION  
PC BOARD BLANK  
6-32 X .375 ROUND HEAD MACHINE SCREW  
6-32 X .500 ROUND HEAD MACHINE SCREW  
# 6 LOCK WASHER  
CHANGE DETAIL: REVISED ITEM 13  
ENGINEERING CONTROL  
MANUFACTURER: No  
LED  
1
1
1
2
SEE BLANK INFO  
1
CF000003  
2
(D6)*  
CF000004  
3
(D11)*  
E106A-13  
4
(D6,D11)*  
(D6,D11)*  
(D6)*  
(D11)*  
(D11)*  
AS REQ E1868  
5
THERMO JOINT COMPOUND  
HEAT SINK,ALUMINUM,EXTRUDED,FOR 1 TO-220  
HEAT SINK,ALUMINUM,EXTRUDED,FOR 1 TO-247,1.5  
# 6 OR # 8 PLAIN WASHER  
1
1
1
1
2
1
S18104-3  
6
S18104-7  
S9262-3  
M19436-2  
S8025-80  
E3768-4  
7
8
9
POTTING TRAY  
10  
11  
12  
13  
SELF TAPPING SCREW  
LABEL  
NOTES:  
N.A. CAUTION: THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY. SEE E2454 BEFORE HANDLING.  
N.B. SECURE P.C. BOARD ASSEMBLY IN PLACE WITH ITEM (10). (2 PLACES, 5.3 +/ .5 IN. LBS).  
AS REQ E3539  
200 g E2527  
ELECTRICAL INSULATING COMPOUND  
EPOXY ENCAPSULATING RESIN  
-
REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW  
N. PRINT L12400-2F0” ON ITEM (11)AND APPLY TO ITEM (9) IN AREA SHOWN.  
C
.
“
N.D.  
N.E.  
N.F.  
DO NOT COAT WITH ENCAPSULATION MATERIAL.  
CONNECTORS MUST BE GREASED WITH ITEM(12) PRIOR TO ENCAPSULATION.  
ENCAPSULATE WITH ITEM(13) EXCEPT WHERE INDICATED ABOVE.  
REFERENCES  
QTY PART NUMBER  
DESCRIPTION  
CONNECTOR,TAB,QC,VERTICAL,1/4,EXTENDED  
4
T13157-24  
B1, B2, B3, B4  
N.D.  
C1, C2, C3, C4, C5, C6,  
16  
S16668-11  
CAPACITOR,CEMO,0.1, 50V,10%  
C7, C8, C9, C10, C11,  
C12, C13, C19, C21, C24  
2
2
1
2
1
1
4
3
3
3
1
5
1
1
1
1
1
1
5
S16668-6  
S13490-173  
S13490-197  
S16668-5  
S13490-19  
S16668-3  
T12199-1  
T12705-59  
T12705-34  
T12705-51  
T12705-62  
T12702-29  
T12702-33  
T12702-58  
T12702-52  
S18248-10  
S18248-4  
S18248-6  
T12704-37  
C14, C15  
CAPACITOR,CEMO,4700pF,50V,10%  
CAPACITOR,PEMF,1.0,63V,10%  
CAPACITOR,ALEL,82,35V,20%,LOW-ESR  
CAPACITOR,CEMO,.022,50V,20%  
CAPACITOR,TAEL,1.8,20V,10%  
CAPACITOR,CEMO,100pF, 100V,5%  
DIODE,AXLDS,1A,400V  
DIODE,AXLDS,3A,600V,UFR  
DIODE,AXLDS,1A,400V,FR,1N4936  
DIODE,FR,TO220,14A,200V,MUR1520  
DIODE,TO247,60A,800V,60EPS08  
ZENER DIODE,1W,15V,5%,1N4744A  
ZENER DIODE,5W,10V,5%,1N5347B  
ZENER DIODE,5W,16V,5%,1N5353B  
ZENER DIODE,1W,5.1V,5%,1N4733A  
CONNECTOR,MOLEX,MINI,PCB,10-PIN  
CONNECTOR,MOLEX,MINI,PCB,4-PIN  
CONNECTOR,MOLEX,MINI,PCB,6-PIN  
TRANSISTOR,P,TO220,3A,100V,TIP32C1  
C16, C18  
C17  
M
AKE PER E1911  
C20, C23  
C22  
TES PER E4151-I  
T
C25  
CAPACITORS = MFD/VOLTS  
RESISTORS =OHMS  
SCHEMATIC REFERENCE G4828-2F0  
D1, D2, D7, D13  
D3, D8, D12  
:
D4, D9, D14  
D5, D6, D10  
D11  
DZ1, DZ2, DZ3, DZ7, DZ8  
DZ4  
DZ5  
9
DZ6  
N.B.  
J31  
N.D.  
N.D.  
N.D.  
,
N.E.  
N.E.  
N.E.  
J32  
,
J33  
,
Q1, Q2, Q9, Q14, Q15  
Q3, Q4, Q10, Q16, Q17,  
Q18, Q19  
7
T12704-68  
TRANSISTOR,NPN,TO226,0.5A,40V,2N4401  
C15  
R16  
R9  
X7  
Q5, Q11, Q20, Q21, Q22,  
Q29  
6
3
8
T12704-69  
T12704-107  
T12704-108  
TRANSISTOR,PNP,TO226,0.5A, 40V,2N4403  
TRANSISTOR,PMF,TO220,40A,100V,IRF5210(SS)  
TRANSISTOR,NMF,TO220,80A,100V,IRF8010(SS)  
R48  
R54  
X5  
N.A. Q6, Q27, Q28  
Q7, Q8, Q12, Q13, Q23,  
DZ7  
X2  
N.A.  
R19  
R14  
R18  
C14  
Q24, Q25, Q26  
Q7  
Q24  
Q8  
Q25  
1
5
2
2
T12704-47  
Q30  
TRANSISTOR,PNP,TO226,0.5A, 300V,MPS-A92  
RESISTOR,MF,1/4W,150,1%  
S19400-1500  
S19400-1501  
S19400-4751  
D11  
R1, R2, R3, R4, R5  
R6, R83  
Q23  
R11  
R41  
X4  
RESISTOR,MF,1/4W,1.50K,1%  
FTP  
B1  
1
D4  
B3  
R7, R8  
RESISTOR,MF,1/4W,4.75K,1%  
D5  
R20  
Q16  
R9, R10, R11, R12, R13,  
R15, R46, R47, R54, R65,  
R66, R67, R92, R93  
R14, R16, R17, R18, R35,  
R48  
X3  
Q13  
X6  
14  
S19400-2212  
RESISTOR,MF,1/4W,22.1K,1%  
R68  
R13  
R10  
Q29  
R92  
R70  
C20  
C6  
Q6  
Q28  
Q27  
Q2  
Q9  
R8  
R73  
Q26  
Q12  
6
S19400-3322  
RESISTOR,MF,1/4W,33.2K,1%  
R84  
C21  
C7  
R60  
R80  
R59  
1
1
3
S19400-1622  
S19400-2671  
S19400-6812  
R19  
R20  
RESISTOR,MF,1/4W,16.2K,1%  
RESISTOR,MF,1/4W,2.67K,1%  
RESISTOR,MF,1/4W,68.1K,1%  
Q15  
R66  
C3  
C8  
R6  
R4  
R21, R22, R50  
R23, R25, R27, R28, R37,  
R51, R68, R70, R71, R72  
R29, R52  
FTP  
5
D10  
R93  
Q4  
R81  
10  
S19400-1002  
RESISTOR,MF,1/4W,10.0K,1%  
B4  
FTP  
FTP  
4
6
C17  
2
2
1
4
1
5
S19400-1333  
S19400-68R1  
S19400-3321  
S19400-1001  
S19400-2213  
S19400-3320  
RESISTOR,MF,1/4W,133K,1%  
RESISTOR,MF,1/4W,68.1,1%  
RESISTOR,MF,1/4W,3.32K,1%  
RESISTOR,MF,1/4W,1.00K,1%  
RESISTOR,MF,1/4W,221K,1%  
RESISTOR,MF,1/4W,332,1%  
C24  
R83  
R69  
R44  
R34  
R30, R31  
R33  
R34, R36, R53, R73  
R38  
R23  
R77  
R78  
R31  
R30  
R61  
R62  
J33  
J32  
X1  
DZ5  
D14  
R39, R56, R85, R86, R87  
R40, R55, R57, R74, R75,  
R76, R77, R78, R79  
R41, R84, R88, R94, R95  
R43, R58, R64, R89  
R44, R59, R60, R61, R62,  
R80, R81  
9
S19400-1000  
RESISTOR,MF,1/4W,100,1%  
5
4
S19400-1821  
S19400-2673  
RESISTOR,MF,1/4W,1.82K,1%  
RESISTOR,MF,1/4W,267K,1%  
N.C.  
7
S25365-51R0  
RESISTOR,STAND-UP,WW,5W,51.0,5%  
N.E.  
2
1
1
1
1
2
1
4
2
1
S18380-8  
R63, R82  
THERMISTOR,PTC,6.7OHMS,320MA  
RESISTOR,MF,1/4W,200,1%  
11  
S19400-2000  
S19400-1212  
S19400-8251  
T12731-9  
R69  
R90  
RESISTOR,MF,1/4W,12.1K,1%  
R91  
RESISTOR,MF,1/4W,8.25K,1%  
R96  
RESISTOR,METAL FILM,1/2W,470,2%  
MOV,14VRMS,100J,20MM  
T13640-26  
S15128-10  
S15128-11  
S15018-13  
S15018-15  
TP2, TP3  
X1  
VOLTAGE REF,ADJ, PRECISION,431I  
IC,COMPARATOR,QUAD,2901N  
X2, X3, X7, X8  
X4, X5  
IC,CMOS,TIMER,PROGRAMMABLE,4536(SS)  
IC,CMOS,GATE,NAND,2-INPUT,QUAD,SCHM(SS)  
N.A.  
N.A. X6  
PROPRIETARY & CONFIDENTIAL:TTO OT  
HIS DOCUME  
N
T CONTAINS P  
R
OPRIETARY INFORMATIO  
N
OWNED BY LIN  
C
OLN GLOBAL, INC. A  
N
D MAY NOT BE  
D
UPLICATED,  
COMMUNICATED  
HER PA  
R
TIES O USE  
R
D
FOR ANY RPOSE WITHOUT THE E  
P
U
X
PRESS  
W
RITTEN PERMISSIO  
N
OF LINC  
OLN GLOBAL, INC.  
MANUFACTURIN  
G
TOLERANCE PER E2056  
IFIE TOLERA CE  
PLACE DECIMALS IS .02 in 0.5 mm)  
LA DECIMALS IS .002 n.  
DEGREE  
") TO REE  
SCA  
L
E:  
DESIGN INFORM  
A
TION  
U
NLESS OTHERWISE SPE  
C
D
N
:
EQUIPMENT TYPE  
:
_1__  
1
ENGIN  
E
WELDERS  
PAGE  
OF ___  
O
N
2
3
.
(
1:1  
DRAWN  
B
Y:  
MAP  
BAM  
-
ON  
P
CE  
i
(
0.05 mm)  
DOCUMENT  
REVISI N:  
DOCUMENT  
IF PRINTED  
O
N
ALL ANGLES IS .5 OF  
A
SUBJECT:  
MATERIAL  
IDLE  
R
/ENGIN  
E
SHUTDOWN  
P.C  
.
BOARD  
MBER:  
E O  
NUL12400-2  
@
A2 SIZE  
NITS:  
MATERIAL TOLERANCE  
("  
AG  
E
NGINEER:  
t
DISPOSITION:  
L124C0E0:-1  
REFEREN  
U
WITH  
DO  
CA  
PUBLISHLEDESTANDARDS.  
DRAWING  
THIS  
AL 9/28/2006  
APPROV  
DATE:  
PROJECT  
CRM34402  
NUMBER:  
UF  
APPROVED:  
INCH  
N
OT  
S
STRB  
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-  
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the  
machine.  
®
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-13  
G-13  
ELECTRICAL DIAGRAMS  
SCHEMATIC - IDLER/ENGINE SHUTDOWN PC BOARD (G4828-2)  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
®
SAE-400 SEVERE DUTY  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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