Lincoln Electric SVM204-A Disconnecting, This plug disables the normal, Engine shut down function

Page 44

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F-4

TROUBLESHOOTING AND REPAIR

 

 

 

 

F-4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Observe Safety Guidelines detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PROBLEMS

POSSIBLE AREAS OF

 

RECOMMENDED

 

 

 

(SYMPTOMS)

MISADJUSTMENT(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

 

 

Major physical or electrical

Contact the Lincoln Electric

 

 

 

 

 

 

damage.

 

Service Department at 1-888-935-

 

 

 

 

 

 

 

 

3877.

 

 

 

 

 

 

 

 

 

 

 

The engine will not crank while

1. Be certain that the battery is

1. Test the fuse located under the

using the electric start function.

properly

connected

and

white cover at the back of the

 

 

adequately charged.

 

control box.

 

 

 

 

 

 

2. Try cranking the engine using

2. Test for battery voltage at lead

 

 

the recoil starter. If the engine

210B where it connects to the

 

 

will still not turn, or the recoil

starter solenoid, while holding

 

 

starter is hard to pull, remove

the switch in the “start” position.

 

 

the spark plug and check for

If voltage is present, the

 

 

water or oil in the cylinder. Also

starter/solenoid assembly is

 

 

check for high oil level.

 

defective; contact the engine

 

 

3. If the engine cranks normally

manufacturer

for

parts

and

 

 

service.

 

 

 

 

 

 

 

while using the recoil starter,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

remove the top cover from the

3. If battery voltage is not present,

 

 

machine ad check the fuse.

check the engine switch, and all

 

 

The fuse is located under the

connectors

and

wires

 

 

white cover of the back of the

connecting the fuse, switch and

 

 

control box.

 

 

starter solenoid. See the wiring

 

 

 

 

 

diagram.

 

 

 

 

 

 

 

 

Engine will not start. The starter

1. If using the recoil starter, be

1. Check for battery voltage at the

motor will crank the engine

sure the engine switch is in the

PC board pin J3-10. (lead #211)

normally.

 

“high” or “auto” position.

 

If voltage is not resent, the

 

 

2. Check that the fuel valve is

engine switch or wire #211 may

 

 

be defective.

 

 

 

 

 

 

open, and that there is

 

 

 

 

 

 

 

 

 

 

 

 

 

 

sufficient, fresh gasoline in the

2. Check PC board ground at pin

 

 

tank.

 

 

J1-2. (lead GND-G)

 

 

 

 

 

3. Be certain that the battery is

3. Place the engine switch in the

 

 

properly

connected

and

“stop” position, unplug engine to

 

 

adequately charged, even if

welder

harness

connector

 

 

using the recoil starter.

 

(P4/J4)

located

inside

the

 

 

4. Check the engine oil level.

 

control box at the bottom left.

 

 

 

CAUTION:

Disconnecting

 

 

5. Check or replace the fuel filter.

this plug disables the normal

 

 

engine shut down function of

 

 

 

 

 

 

 

6. Check or replace air filter.

 

the engine switch.

 

 

 

 

 

7. Check the spark plug. Clean or

 

 

 

 

 

 

 

 

replace if necessary.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 Safety California Proposition 65 WarningsElectric Shock can kill ARC Rays can burn Can be dangerousPowered equipment Welding CuttingCylinder may explode Sparks can cause fire or If damaged ExplosionPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcSafety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Outback 185 K2706-1AC Auxiliary Power Bore x StrokeStoring Safety PrecautionsLocation and Ventilation PRE-OPERATION Engine Service StackingTilting OILCable Size and Length Cable Amps Length 30% Duty CycleCable Installation Machine GroundingAuxiliary Power Receptacles Premises WiringCircuit Breakers See Figure A.1Table A.2 Electrical Device USE with the Outback Type Common Electrical Devices Possible ConcernsTable of Contents Operation Section Safety Instructions OperationGraphic Symbols Used on this Equipment or in this Manual OIL AIR Cleaner FuelWork Clamp Ground Auxiliary Power BreakerDesign Features Advantages Operational Features and ControlsGeneral Description Recommended ApplicationsWhen in Auto Idle WELDER/GENERATOR ControlsEngine Operation Stopping the EngineOnly qualified Personnel should install, use, or With a Lincoln WireService this equipment Electric Shock can kill120V Receptacle Operation 240V Receptacle OperationTable B.3 Auxiliary Power Applications Outback Table of Contents Accessories Section Accessories OPTIONS/ACCESSORIESTable of Contents Maintenance Section Maintenance Safety Precautions Tighten dipstick firmly before startingTo service the pre-cleaner Kohler CSMaintenance Outback 1TABLE of CONTENTS-THEORY of Operation Section E-1 Engine STARTING, Protection and Battery Charging Theory of OperationEngine STARTING, Protection and Battery Charging contin- ued Automatic Idle System Figure E.4 Automatic Idle SystemBuilding Output AC Output Generating PowerFlashing Generating Power DC Weld OutputWeld 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 Disconnecting This plug disables the normalEngine switch Engine shut down functionTroubleshooting and Repair Problems Symptoms Adjustment procedure Engine RPM adjustmentProcedure Troubleshooting and Repair Voltage, and resistance Tests Perform the stator resistance Voltage testsBrush and slip ring service EngineCircuit tests Service procedureBrush and slip Ring Outback Engine RPM Adjustment Procedure Test DescriptionEngine RPM Adjustment Procedure Strobe-Tach MethodControl Lever Frequency Counter MethodTOP View of Engine Vibratach MethodThrottle Adjustment Procedure Low Idle Adjustment Throttle Adjustment ProcedureHigh Idle Adjustment Brush and Slip Ring Service Procedure Procedure DescriptionBrush and Slip Ring Service Procedure Figure F.5 Brush Holder Assembly LocationCleaning Slip Rings Cable TIE BrushesOutback Rotor Flashing and Voltage Test Set the output control to maximum Battery Charging System Test Figure F.8 Charging System Stator Voltage Test Figure F.9 High and LOW Idle Adjustment Stator Voltage TestRotor Resistance and Ground Test Static Slip Rings Brushes Rotor Resistance and Ground Test StaticRotor Resistance and Ground Test Dynamic Rotor Resistance and Ground Test Dynamic Figure F.11 Brush and Slip Ring LocationsStator Short Circuit and Ground Test Perform Case Cover Removal Procedure Stator Short Circuit and Ground TestWeld Boost System Test Figure F.12 High and LOW Idle Adjustment Weld Boost System TestCase Cover Removal and Replacement Procedure Case Cover Removal and Replacement Procedure Figure F.13 Case Cover RemovalFuel 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 Control BOX Removal and Replacement Procedure Perform the Fuel Tank and Enclosure Removl ProcedureMounting Bracket Battery Outback Stator Removal and Replacement Procedure Stator Removal and Replacement Procedure Perform the Control Box Removal ProcedureInstalling the stator assembly Figure F.19 Nuts & Rubber Engine MountsTolerance Ring Stator Rotor Removal and Replacement Procedure Replacing the Rotor Rotor Removal and Replacement ProcedurePerform the Stator Removal Procedure Retest After Repair No-load test valuesFull load test values Volt receptaclesOutback Table of Contents Diagram Section Wiring Diagram Outback OUTBacKSchEmaTic cOmplETE machiNE cODE 11516 G6205 Equipmenttype