Lincoln Electric SVM204-A service manual Safety Precautions, Location and Ventilation, Storing

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A-3

INSTALLATION

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SAFETY PRECAUTIONS

Read this entire installation section before you start installation.

WARNING

Do not attempt to use this equipment until you have thoroughly read all operating and mainte- nance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.

LOCATION AND VENTILATION

Whenever you use the OUTBACK® 185, be sure that clean cooling air can flow around the machine’s gasoline engine and the generator. Avoid dusty, dirty areas. Also, keep the machine away from heat sources. Do not place the back end of the generator anywhere near hot engine exhaust from another machine. And of course, make sure that engine exhaust is ventilated to an open, outside area.

The OUTBACK® 185 must be used outdoors. Do not set the machine in puddles or otherwise submerge it in water. Such practices pose safety hazards and cause improper operation and corrosion of parts.

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Hazards of Electric Shock, Engine Exhaust & Moving Parts

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet cloth- ing.

Insulate yourself from work and ground.

Always wear dry insulating gloves.

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust outside.

• Do not stack anything on or near the engine.

MOVING PARTS can injure.

Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

Only qualified personnel should install, use, or service this equipment.

Always operate the OUTBACK® 185 with the case roof on and all machine components completely assembled. This will help to protect you from the dangers of moving parts, hot metal surfaces, and live electrical devices.

STORING

1.Store the machine in a cool, dry place when it is not in use. Protect it from dust and dirt. Keep it where it can not be accidentally damaged from construction activities, moving vehicles and other hazards.

2.If you will be storing the machine for over 30 days, you should drain the fuel to protect fuel system and carbure- tor parts from gum deposits. Empty all fuel from the tank and run the engine until it stops from lack of fuel.

3.You can store the machine for up to 24 months if you use a stabilizing Additive in the fuel system. Mix the additive with the fuel in the tank and run the engine for a short time to circulate the additive through the carburetor.

4.While the engine is still warm, drain the oil and refill with fresh 10W30 oil.

5.Remove the spark plug and pour approximately 1/2 ounce (15ml) of engine oil into the cylinder. Replace the spark plug and crank the engine slowly to distribute the oil.

6.Clean any dirt and debris from the cylinder and cylinder head fins and housing, rotating screen, and muffler areas.

7.Store in a clean, dry area.

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 PowerStoring Safety PrecautionsLocation and Ventilation 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 SystemBuilding Output AC Output Generating PowerFlashing Weld Boost Generating PowerDC Weld Output Weld Output Control1TABLE of Contents Troubleshooting and Repair F-1 Locate PROBLEM SYMPTOM Troubleshooting and RepairHOW to USE Troubleshooting Guide PC Board Troubleshooting Procedures Engine shut down function DisconnectingThis plug disables the normal Engine switchTroubleshooting and Repair Problems Symptoms Adjustment procedure Engine RPM adjustmentProcedure Troubleshooting and Repair Tests Perform the stator resistance Voltage tests Voltage, and resistanceEngine Brush and slip ring serviceCircuit tests Service procedureBrush and slip Ring Outback Test Description Engine RPM Adjustment ProcedureStrobe-Tach Method Engine RPM Adjustment ProcedureFrequency Counter Method Control LeverVibratach Method TOP View of EngineThrottle Adjustment Procedure Low Idle Adjustment Throttle Adjustment ProcedureHigh 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 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 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 Replacing the Rotor Rotor Removal and Replacement ProcedurePerform the Stator Removal Procedure 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