Troubleshooting and Repair

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F-8	TROUBLESHOOTING AND REPAIR	F-8

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS	POSSIBLE AREAS OF		RECOMMENDED
(SYMPTOMS)	MISADJUSTMENT(S)		COURSE OF ACTION

	OUTPUT PROBLEMS
The engine will not go to high idle	1. Poor connection in weld circuit;		1. Unplug P4/J4 connector and
when a welding or auxiliary load	check cables, connectors, work		measure	the idle			solenoid
is applied. Engine idles up	clamp and electrode holder.		resistance		between			leads
normally and outputs are normal	Check that work clamp is		213B and		215A.		it	should
when the engine switch is placed	making a good connection to		measure about 15 ohms.
in the “high” position.	the work piece.		Measure the resistance from
	2. Load too low to activate the idle		lead 213B or lead 215A to
			chassis ground.			Resistance
	circuit.	Plug in a device that
			should be very high; 500,000
	applies a load of 100 watts or
			(500K)	ohms		or		higher.
	more.
			Replace the solenoid if the

	NOTE: Some tools and devices		resistance		is	significantly
			different.
	check for “good” power before

	fully turning on. These devices		2. Reconnect P4/J4 and start the
	will require the machine to be		machine placing the engine
	placed in the “high” position
			switch in the high” position.
	before they will function.
			Plug in a 100-watt light bulb.

			Check for AC voltage at leads
			260 (J2-3) and 261 (J2-4). The
			meter should read about 1.2
			volts. If voltage is significantly
			lower, replace			the	toroidal
			current transformer.
			3. If the above readings are
			normal, replace the PC board.

No weld or auxiliary output –	1. Make sure there is no load on		1. The brushes and slip rings may
Engine runs normally.	the machine. Disconnect all		be worn or faulty. Perform the
	cables and cords from the weld		brush and slip ring service
	output	terminals and the	procedure.
	auxiliary receptacles. Check for		2. With the engine running, check
	DC open circuit voltage (OCV)
	(About 70 to 80 volts) at the		for battery voltage at the PC
			board, J3-9 (lead #208A). If
	weld output terminals and check
			voltage is not present, check
	for AC auxiliary voltage at the
			conductors and connection at
	120 and 240 VAC receptacles.
			leads 208A, 208, and the

	2. Check that circuit breakers are		engine wiring leading to the
	not tripped.		engine charging system. If the
			connections are good, the
			battery charging system may
			be faulty. Contact a qualified
			engine repair technician.

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.

Lincoln Electric SVM204-A service manual Troubleshooting and Repair

OUTPUT PROBLEMS

OUTBACK® 185