Lincoln Electric SVM204-A service manual Troubleshooting and Repair

Page 45

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F-5

TROUBLESHOOTING AND REPAIR

 

 

 

F-5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Observe Safety Guidelines detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

 

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

 

RECOMMENDED

 

(SYMPTOMS)

 

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

 

(Continued)

 

8. Observe the oil level indicator

Reconnect P4/J4 to shut the

 

 

light while cranking the engine.

engine down.

 

 

 

 

 

If the light is blinking while

Attempt to start the engine

 

 

cranking the engine, the oil level

 

 

using the recoil starter; if the

 

 

may be low, or the oil level

 

 

engine starts, check lead #212

 

 

system may be faulty. Contact

 

 

for faulty insulation. If lead

 

 

the engine manufacturer.

 

 

#212 is good, replace the PC

 

 

 

 

 

 

board.

 

 

 

 

 

 

 

If the engine fails to start, have

 

 

 

the engine and oil level system

 

 

 

checked by a qualified engine

 

 

 

service technician.

 

 

 

 

 

The engine will not shut down.

 

1. Place the engine switch in the

 

 

 

“stop” position and check for

 

 

 

battery voltage at the PC board

 

 

 

pin J3-10. (lead #211)

If

 

 

 

voltage is present, the switch is

 

 

 

defective.

 

 

 

 

 

 

 

2. Locate

and

ground

the

 

 

 

brown/white

lead

from

the

 

 

 

engine ignition magneto. If the

 

 

 

engine still will not shut down,

 

 

 

the engine ignition magneto

 

 

 

may be defective. Contact a

 

 

 

qualified engine technician.

 

 

 

3. If the engine shuts down when

 

 

 

the

brown/white

lead

is

 

 

 

grounded, check wiring and

 

 

 

connections at leads #212,

 

 

 

GND-I, GND-J, and the brown

 

 

 

leads between connector J4/P4

 

 

 

and

the

engine

ignition

 

 

 

magneto. If these leads and

 

 

 

connections are 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.

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 StrokeSafety Precautions Location and VentilationStoring 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 SystemGenerating Power FlashingBuilding Output AC Output DC Weld Output Generating PowerWeld Output Control Weld Boost1TABLE of Contents Troubleshooting and Repair F-1 Troubleshooting and Repair HOW to USE Troubleshooting Guide Locate PROBLEM SYMPTOM PC Board Troubleshooting Procedures This plug disables the normal DisconnectingEngine switch Engine shut down functionTroubleshooting and Repair Problems Symptoms Engine RPM adjustment ProcedureAdjustment procedure Troubleshooting and Repair Tests Perform the stator resistance Voltage tests Voltage, and resistanceEngine Brush and slip ring serviceService procedure Brush and slip RingCircuit 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 Throttle Adjustment Procedure High Idle AdjustmentLow 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 Removal and Replacement Procedure Perform the Case Cover Removal 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 Rotor Removal and Replacement Procedure Perform the Stator Removal 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