Lincoln Electric SVM204-A Engine STARTING, Protection and Battery Charging contin- ued

Page 37

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E-3

THEORY OF OPERATION

E-3

 

FIGURE E.3 - ENGINE STARTING, PROTECTION AND BATTERY CHARGING

 

 

 

 

 

 

 

CURRENT

120 VAC RECEPTACLES

 

240 VAC

 

 

 

 

 

 

 

SENSOR

 

 

 

 

 

 

 

 

 

 

RECEPTACLE

 

 

 

 

 

 

 

 

 

 

 

OIL LEVEL

 

 

 

 

 

CB1

CB3

 

OIL

 

INDICATOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LEVEL

 

 

 

 

 

 

 

CB2

CB4

 

MODULE

 

 

 

 

 

 

 

(KOHLER)

 

 

 

 

 

REACTOR

 

 

 

 

OIL LEVEL

 

 

AUXIIARY WINDINGS

 

 

 

 

 

 

SWITCH

 

RINGS

 

STATOR

 

 

 

 

 

 

 

 

SLIP

 

 

 

 

 

+

 

 

 

 

_ +

 

WELD

 

OUTPUT

CHOKE

 

 

 

 

 

 

 

 

OUTPUT

 

 

IGNITION

ENGINE

 

ROTOR

WINDINGS

 

RECTIFIER

 

 

 

 

 

 

STUDS

 

 

 

 

 

 

 

 

(2 PHASE)

 

 

 

 

 

 

BRUSHES

 

 

 

 

 

 

 

STARTER /

ALTERNATOR

IDLE

EXCITER

 

 

 

 

 

 

SOLENOID

SOLENOID

WINDING

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10 AMP

 

 

 

 

 

BOOST

 

 

 

 

 

 

 

 

 

WINDING

 

 

 

 

FUSE

 

 

 

 

 

 

 

 

 

 

OFFAUTO

 

 

 

 

 

 

 

 

_

+

HIGH

 

 

 

 

 

 

 

START

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BATTERY

 

 

ENGINE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SHUTDOWN

 

 

 

 

 

 

 

 

 

 

RELAY

 

 

 

OUTPUT

 

 

 

 

 

 

 

AUTOMATIC

OUTPUT

CONTROL

 

 

 

 

 

 

 

IDLER

CONTROL CIRCUIT

 

 

 

 

 

 

 

 

CIRCUIT

 

 

 

 

 

 

 

HOUR

 

 

 

 

 

 

 

 

 

 

METER

 

FIELD / CONTROL PC BOARD

 

 

 

 

 

 

 

 

 

 

 

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ENGINE STARTING, PROTECTION AND BATTERY CHARGING (contin- ued)

BATTERY CHARGING

The Kohler engine has a built-in battery charging sys- tem. Output from the charging system is applied to the PC board where it is stabilized by the battery and then used to power the board electronics, the generator flashing system, and the hour meter. The remaining output exits the PC board, is routed through a fuse located inside the control box, and applied to the bat- tery.

NOTE: The engine charging system must be function- al for the Outback® 185 to produce weld or auxiliary output.

NOTE: The battery must remain connected at all times. If the battery is disconnected while the machine is run- ning, unstable voltage from the charging system will likely cause the PC board electronics to malfunction and may cause permanent damage to the PC board.

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion

OUTBACK® 185

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Page 36 Page 38
Contents Outback California Proposition 65 Warnings SafetyCan be dangerous Electric Shock can kill ARC Rays can burnWelding Cutting Powered equipmentCylinder may explode Sparks can cause fire or If damaged ExplosionSûreté Pour Soudage a L’Arc Précautions DE SûretéSafety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Outback 185 K2706-1 InstallationAC Auxiliary Power Bore x StrokeLocation and Ventilation Safety PrecautionsStoring Stacking PRE-OPERATION Engine ServiceTilting OILCable Amps Length 30% Duty Cycle Cable Size and LengthMachine Grounding Cable InstallationPremises Wiring Auxiliary Power ReceptaclesCircuit Breakers See Figure A.1Type Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the OutbackTable of Contents Operation Section Operation Safety InstructionsOIL AIR Cleaner Fuel Graphic Symbols Used on this Equipment or in this ManualWork Clamp Ground Auxiliary Power BreakerOperational Features and Controls Design Features AdvantagesGeneral Description Recommended ApplicationsWELDER/GENERATOR Controls When in Auto IdleStopping the Engine Engine OperationWith a Lincoln Wire Only qualified Personnel should install, use, orService this equipment Electric Shock can kill240V Receptacle Operation 120V Receptacle OperationTable B.3 Auxiliary Power Applications Outback Table of Contents Accessories Section OPTIONS/ACCESSORIES AccessoriesTable of Contents Maintenance Section Maintenance Tighten dipstick firmly before starting Safety PrecautionsKohler CS To service the pre-cleanerMaintenance Outback 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Engine STARTING, Protection and Battery ChargingEngine STARTING, Protection and Battery Charging contin- ued Figure E.4 Automatic Idle System Automatic Idle SystemFlashing Generating PowerBuilding Output AC Output DC Weld Output Generating PowerWeld Output Control Weld Boost1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide Troubleshooting and RepairLocate PROBLEM SYMPTOM PC Board Troubleshooting Procedures This plug disables the normal DisconnectingEngine switch Engine shut down functionTroubleshooting and Repair Problems Symptoms Procedure Engine RPM adjustmentAdjustment procedure Troubleshooting and Repair Tests Perform the stator resistance Voltage tests Voltage, and resistanceEngine Brush and slip ring serviceBrush and slip Ring Service procedureCircuit tests Outback Test Description Engine RPM Adjustment ProcedureStrobe-Tach Method Engine RPM Adjustment ProcedureFrequency Counter Method Control LeverVibratach Method TOP View of EngineThrottle Adjustment Procedure High Idle Adjustment Throttle Adjustment ProcedureLow Idle Adjustment Procedure Description Brush and Slip Ring Service ProcedureFigure F.5 Brush Holder Assembly Location Brush and Slip Ring Service ProcedureCable TIE Brushes Cleaning Slip RingsOutback Rotor Flashing and Voltage Test Set the output control to maximum Battery Charging System Test Figure F.8 Charging System Stator Voltage Test Stator Voltage Test Figure F.9 High and LOW Idle AdjustmentRotor Resistance and Ground Test Static Rotor Resistance and Ground Test Static Slip Rings BrushesRotor Resistance and Ground Test Dynamic Figure F.11 Brush and Slip Ring Locations Rotor Resistance and Ground Test DynamicStator Short Circuit and Ground Test Stator Short Circuit and Ground Test Perform Case Cover Removal ProcedureWeld Boost System Test Weld Boost System Test Figure F.12 High and LOW Idle AdjustmentCase Cover Removal and Replacement Procedure Figure F.13 Case Cover Removal Case Cover Removal and Replacement ProcedureFuel Tank and Enclosure Removal and Replacement Procedure Perform the Case Cover Removal Procedure Removal and Replacement ProcedureFuel Tank and Enclosure Mounting Bracket Battery Outback Control BOX Removal and Replacement Procedure Perform the Fuel Tank and Enclosure Removl Procedure Control BOX Removal and Replacement ProcedureMounting Bracket Battery Outback Stator Removal and Replacement Procedure Perform the Control Box Removal Procedure Stator Removal and Replacement ProcedureFigure F.19 Nuts & Rubber Engine Mounts Installing the stator assemblyTolerance Ring Stator Rotor Removal and Replacement Procedure Perform the Stator Removal Procedure Rotor Removal and Replacement ProcedureReplacing the Rotor No-load test values Retest After RepairFull load test values Volt receptaclesOutback Table of Contents Diagram Section OUTBacK Wiring Diagram OutbackSchEmaTic cOmplETE machiNE cODE 11516 G6205 Equipmenttype
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