Lincoln Electric SVM204-A service manual Weld Boost System Test

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F-35	TROUBLESHOOTING AND REPAIR	F-35

WELD BOOST SYSTEM TEST

WARNING

Service and repair should be performed only by 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 functionality of the weld boost system. This test should be done if the weld terminal open circuit voltage and engine RPM are normal, but the machine weld output is low.

MATERIALS NEEDED

Resistive load bank

Misc. hand tools

Multimeter

OUTBACK® 185

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Contents Outback California Proposition 65 Warnings SafetyCan be dangerous Electric Shock can kill ARC Rays can burnSparks can cause fire or If damaged Explosion Powered equipmentWelding Cutting Cylinder may explodeSûreté 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 Bore x Stroke InstallationTechnical Specifications Outback 185 K2706-1 AC Auxiliary PowerSafety Precautions Location and VentilationStoring OIL PRE-OPERATION Engine ServiceStacking TiltingCable Amps Length 30% Duty Cycle Cable Size and LengthMachine Grounding Cable InstallationSee Figure A.1 Auxiliary Power ReceptaclesPremises Wiring Circuit BreakersType Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the OutbackTable of Contents Operation Section Operation Safety InstructionsBreaker Graphic Symbols Used on this Equipment or in this ManualOIL AIR Cleaner Fuel Work Clamp Ground Auxiliary PowerRecommended Applications Design Features AdvantagesOperational Features and Controls General DescriptionWELDER/GENERATOR Controls When in Auto IdleStopping the Engine Engine OperationElectric Shock can kill Only qualified Personnel should install, use, orWith a Lincoln Wire Service this equipment240V 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 Weld Boost Generating PowerDC Weld Output Weld Output Control1TABLE of Contents Troubleshooting and Repair F-1 Troubleshooting and Repair HOW to USE Troubleshooting GuideLocate PROBLEM SYMPTOM PC Board Troubleshooting Procedures Engine shut down function DisconnectingThis plug disables the normal Engine switchTroubleshooting 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 Volt receptacles Retest After RepairNo-load test values Full load test valuesOutback Table of Contents Diagram Section OUTBacK Wiring Diagram OutbackSchEmaTic cOmplETE machiNE cODE 11516 G6205 Equipmenttype