Lincoln Electric SVM204-A instruction

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

Contents

Outback California Proposition 65 Warnings Safety Can be dangerous Electric Shock can kill ARC Rays can burn Welding Cutting Powered equipmentCylinder may explode Sparks can cause fire or If damaged Explosion Sûreté Pour Soudage a L’Arc Précautions DE Sûreté Safety 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 Stroke Storing Safety PrecautionsLocation and Ventilation Stacking PRE-OPERATION Engine ServiceTilting OIL Cable Amps Length 30% Duty Cycle Cable Size and Length Machine Grounding Cable Installation Premises Wiring Auxiliary Power ReceptaclesCircuit Breakers See Figure A.1 Type Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the Outback Table of Contents Operation Section Operation Safety Instructions OIL AIR Cleaner Fuel Graphic Symbols Used on this Equipment or in this ManualWork Clamp Ground Auxiliary Power Breaker Operational Features and Controls Design Features AdvantagesGeneral Description Recommended Applications WELDER/GENERATOR Controls When in Auto Idle Stopping the Engine Engine Operation With a Lincoln Wire Only qualified Personnel should install, use, orService this equipment Electric Shock can kill 240V Receptacle Operation 120V Receptacle Operation Table B.3 Auxiliary Power Applications Outback Table of Contents Accessories Section OPTIONS/ACCESSORIES Accessories Table of Contents Maintenance Section Maintenance Tighten dipstick firmly before starting Safety Precautions Kohler CS To service the pre-cleaner Maintenance Outback 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Engine STARTING, Protection and Battery Charging Engine STARTING, Protection and Battery Charging contin- ued Figure E.4 Automatic Idle System Automatic Idle System Building Output AC Output Generating PowerFlashing DC Weld Output Generating PowerWeld Output Control Weld Boost 1TABLE 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 function Troubleshooting and Repair Problems Symptoms Adjustment procedure Engine RPM adjustmentProcedure Troubleshooting and Repair Tests Perform the stator resistance Voltage tests Voltage, and resistance Engine Brush and slip ring service Circuit tests Service procedureBrush and slip Ring Outback Test Description Engine RPM Adjustment Procedure Strobe-Tach Method Engine RPM Adjustment Procedure Frequency Counter Method Control Lever Vibratach Method TOP View of Engine Throttle Adjustment Procedure Low Idle Adjustment Throttle Adjustment ProcedureHigh Idle Adjustment Procedure Description Brush and Slip Ring Service Procedure Figure F.5 Brush Holder Assembly Location Brush and Slip Ring Service Procedure Cable TIE Brushes Cleaning Slip Rings Outback 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 Adjustment Rotor Resistance and Ground Test Static Rotor Resistance and Ground Test Static Slip Rings Brushes Rotor Resistance and Ground Test Dynamic Figure F.11 Brush and Slip Ring Locations Rotor Resistance and Ground Test Dynamic Stator Short Circuit and Ground Test Stator Short Circuit and Ground Test Perform Case Cover Removal Procedure Weld Boost System Test Weld Boost System Test Figure F.12 High and LOW Idle Adjustment Case Cover Removal and Replacement Procedure Figure F.13 Case Cover Removal Case Cover Removal and Replacement Procedure Fuel 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 Procedure Mounting Bracket Battery Outback Stator Removal and Replacement Procedure Perform the Control Box Removal Procedure Stator Removal and Replacement Procedure Figure F.19 Nuts & Rubber Engine Mounts Installing the stator assembly Tolerance 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 receptacles Outback Table of Contents Diagram Section OUTBacK Wiring Diagram Outback SchEmaTic cOmplETE machiNE cODE 11516 G6205 Equipmenttype