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D-2
COMMUTATOR AND BRUSH
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.
Shifting of the brushes may result in:
- Change in machine output
- Commutator Damage
- Excessive brush wear
Periodically inspect the commutator, slip rings and
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.
Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance person
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.
NOTE: If the welder is used in dirty or dusty locations,
or if the welder is not used for prolonged periods of
time, it may be necessary to clean the commutator and
slip rings more often.
Replace brushes when they wear within 1/4" of the 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
person seat these brushes by lightly stoning the com-
mutator as the armature rotates at full speed until con-
tact is made across the full face of the brushes. After
stoning, blow out the dust with low pressure air.
To seat the slip ring brushes, position the brushes in
place. Then slide one end of a piece of fine sandpaper
between slip rings and brushes with the coarse side
against the brushes. With slight additional finger pres-
sure on top of the brushes, pull the sandpaper around
the circumference of the rings, in direction of rotation
only - until brushes seat properly. In addition, stone
slip ring with a fine stone. Brushes must be seated
100%.
Arcing or excessive exciter brush wear indicates a pos-
sible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.
MAINTENANCE
COOLING SYSTEM
The SAE-500™ is equipped with a pressure radiator.
Keep the radiator cap tight to prevent loss of coolant.
Clean and flush the cooling system periodically to pre-
vent clogging the passage and overheating the engine.
When antifreeze is needed, always use the permanent
type.
PRE FILTER / WATER SEPARATOR
When working on the fuel system
------------------------------------------------------------------------
The SAE-500™ is equipped with a Fuel Pre-
Filter/Water Separator Assembly located before the
lift pump mounted to the fuel tank rail.
FUEL PRE-FILTER/WATER SEPARATOR ASSEMBLY
The pre-filter is a 154 micron screen designed to pro-
tect against gross fuel contamination of the water sep-
arator element and the Secondary Fuel Filter.
CLEANING FUEL FILTER (ELEMENT TYPE ONLY)
(See Figure D.1)
1. Close the fuel cock (3).
2. Unscrew the retaining ring (6) and remove the filter cup (5)
and rinse the inside with kerosene.
3. Take out the element (4) and dip it in kerosene to rinse.
4. After cleaning, reassemble the fuel filter, keeping out dust
and dirt.
5. Bleed the fuel system.
IMPORTANT
• If dust and dirt enter the fuel, fuel injection pump and
injection nozzle will wear quickly. To prevent this, be
sure to clean the filter cup (5) periodically.
SAE-500™
WARNING
• Keep unguarded lights away, do not
smoke !
• Do not spill fuel !
FIGURE D.1
(1)
COCK BODY
(2)
(3)
(4)
FILTER ELEMENT
(5)
FILTER CUP
(6)
RETAININR RING
D-2
AIR VENT PLUG
FUEL COCK
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