Lincoln Electric SVM204-A service manual 1TABLE of Contents Troubleshooting and Repair F-1

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Return to Master TOC

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F-1TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1

How to Use Troubleshooting Guide	. .F-2
PC Board Troubleshooting Procedures	. .F-3
Troubleshooting Guide	. .F-4
Test Procedures	.F-13
Engine RPM Adjustment Procedure	.F-13
Throttle Adjustment Procedure	.F-17
Brush and Slip Ring Procedure	.F-19
Rotor Flashing and Voltage	.F-23
Battery Charging System	F-25
Stator Voltage Test	.F-27

Rotor Resistance and Ground Test (Static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29 Rotor Resistance and Ground Test (Dynamic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-31 Stator Short Circuit and Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33 Weld Boost System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-35

Case Cover Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-37 Fuel Tank and Enclosure Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-39 Control Box Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-43 Stator Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47

Rotor Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-51 Retest and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-53

OUTBACK® 185

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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 StrokeStoring Safety PrecautionsLocation and Ventilation 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 SystemBuilding Output AC Output Generating PowerFlashing DC Weld Output Generating PowerWeld Output Control Weld Boost1TABLE of Contents Troubleshooting and Repair F-1 Locate PROBLEM SYMPTOM Troubleshooting and RepairHOW to USE Troubleshooting Guide PC Board Troubleshooting Procedures This plug disables the normal DisconnectingEngine switch Engine shut down functionTroubleshooting and Repair Problems Symptoms Adjustment procedure Engine RPM adjustmentProcedure Troubleshooting and Repair Tests Perform the stator resistance Voltage tests Voltage, and resistanceEngine Brush and slip ring serviceCircuit tests Service procedureBrush and slip Ring Outback Test Description Engine RPM Adjustment ProcedureStrobe-Tach Method Engine RPM Adjustment ProcedureFrequency Counter Method Control LeverVibratach Method TOP View of EngineThrottle Adjustment Procedure Low Idle Adjustment Throttle Adjustment ProcedureHigh 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 Fuel Tank and Enclosure Removal and Replacement ProcedurePerform the Case Cover Removal Procedure 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 Replacing the Rotor Rotor Removal and Replacement ProcedurePerform the Stator Removal Procedure 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