Lincoln Electric SVM204-A service manual WELDER/GENERATOR Controls, When in Auto Idle

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B-5

OPERATION

B-5

 

CONTROLS AND SETTINGS All welder/generator controls are located on the Output Control Panel. Gasoline engine controls are mounted on the engine. See Figure B.1 and the figures in engine operation section.

OUTPUT PANEL CONTROLS

10

1

9

7

2

12

 

8

11

65

3 or 4

FIGURE B.1

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WELDER/GENERATOR CONTROLS

See Figure B.1 for the location of the following features:

1.CURRENT CONTROL DIAL: Adjusts continuous cur- rent output. The amperages on the dial correspond to the approximate amperages needed for specific Lincoln welding electrodes.

2.30 AMP CIRCUIT BREAKER: Provide separate over- load current protection for the 120 Volt and 240 Volt Receptacles

3.WELD POSITIVE OUTPUT TERMINAL: Provides the connection point for either the electrode holder or the work cable. (Because the OUTBACK® 185 is a DC output machine, either output terminal can be used for either cable.)

4.WELD NEGATIVE OUTPUT TERMINAL: Provides the connection point for either the electrode holder or the work cable. (Because the OUTBACK®185 is a DC out- put machine, either output terminal can be used for either cable.)

5.GROUND STUD: Provides a connection point for con- necting the machine case to earth ground for the safest grounding procedure.

6.CIRCUIT BREAKER: Provides overload protection for weld output terminals.

7.CIRCUIT BREAKERS (2): Provide separate overload cur- rent protection for the 120 volt and 240 volt receptacles

8.240 VOLT RECEPTACLE: Connection point for supply- ing 250 volt power to operate one electrical device.

9.120 VOLT DUPLEX RECEPTACLES (2): Connection point for supplying 120 volt power to operate devices needed for maintenance purposes.

10.HOUR METER: Records the time that the engine has run for maintenance purposes.

11.ENGINE CHOKE: Engine starting aid.

12.ENGINE SWITCH:

Used to start the engine, Select High Idle or Auto Idle while the engine is running and stops the engine.

When placed in the “OFF” position, the ignition circuit is de-energized to shut down the engine.

When held in the “START” position, the engine starter motor is energized.

When in “HIGH IDLE” ( ) position, the engine will run continuously at high idle.

 

When in “AUTO IDLE” (

/

) position, the

 

engine will run continuously and the idler operates as

 

follows:

 

 

Welding

 

 

 

When the electrode touches the work, the welding

 

arc is initiated and the engine accelerates to full

 

speed. After welding ceases (and no auxiliary power

 

is being drawn), the engine will return to low idle after

 

approximately 10 to 14 seconds.

 

Auxiliary Power

 

 

 

With the engine running

at low

idle and auxiliary

power for lights or tools is drawn (approximately 0- 150 watts or greater) from the receptacles, the engine will accelerate to high speed. If no power is being drawn from the receptacles (and not welding) for 10-14 seconds, the idler reduces the engine speed to low idle.

OUTBACK® 185

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Contents Outback California Proposition 65 Warnings SafetyCan be dangerous Electric Shock can kill ARC Rays can burnWelding Cutting Powered equipmentCylinder may explode Sparks can cause fire or If damaged ExplosionSûreté 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 Technical Specifications Outback 185 K2706-1 InstallationAC Auxiliary Power Bore x StrokeSafety Precautions Location and VentilationStoring Stacking PRE-OPERATION Engine ServiceTilting OILCable Amps Length 30% Duty Cycle Cable Size and LengthMachine Grounding Cable InstallationPremises Wiring Auxiliary Power ReceptaclesCircuit Breakers See Figure A.1Type Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the OutbackTable of Contents Operation Section Operation Safety InstructionsOIL AIR Cleaner Fuel Graphic Symbols Used on this Equipment or in this ManualWork Clamp Ground Auxiliary Power BreakerOperational Features and Controls Design Features AdvantagesGeneral Description Recommended ApplicationsWELDER/GENERATOR Controls When in Auto IdleStopping the Engine Engine OperationWith a Lincoln Wire Only qualified Personnel should install, use, orService this equipment Electric Shock can kill240V 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 DC Weld Output Generating PowerWeld Output Control Weld Boost1TABLE of Contents Troubleshooting and Repair F-1 Troubleshooting and Repair HOW to USE Troubleshooting GuideLocate PROBLEM SYMPTOM PC Board Troubleshooting Procedures This plug disables the normal DisconnectingEngine switch Engine shut down functionTroubleshooting 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 No-load test values Retest After RepairFull load test values Volt receptaclesOutback Table of Contents Diagram Section OUTBacK Wiring Diagram OutbackSchEmaTic cOmplETE machiNE cODE 11516 G6205 Equipmenttype