Lincoln Electric SVM204-A Electric Shock can kill, Do not touch electrically live parts, Ing

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B-7

OPERATION

B-7

 

 

 

 

 

 

 

 

 

 

 

 

 

WELDING OPERATION

4.

Insert the electrode into the electrode holder.

 

 

 

 

 

 

 

 

 

 

 

 

5.

Set the current control dial to the desired output

 

 

 

 

 

 

 

current .

 

 

 

 

WARNING

 

 

 

 

 

 

 

 

 

6.

Start the gasoline engine.

 

 

 

ELECTRIC SHOCK can kill.

 

 

 

See ENGINE OPERATION in this section of

 

 

• Do not touch electrically live parts

 

the manual.

 

 

 

7.

Strike an arc and begin welding.

 

 

or electrode with skin or wet cloth-

 

 

 

 

 

 

 

ing.

AFTER YOU FINISH THE WELD:

 

 

• Insulate yourself from work and

 

 

 

 

 

 

 

 

ground.

1.

Stop the gasoline engine.

See ENGINE OPERA-

 

 

Always wear dry insulating gloves.

 

 

 

TION in this section of the manual.

 

 

 

 

 

 

 

 

 

ENGINE EXHAUST can kill.

 

 

 

 

 

2.

Allow the electrode and work to cool completely.

 

 

 

 

 

 

 

 

• Use in open, well ventilated areas

 

3.

Remove the work clamp from the work.

 

 

or vent exhaust outside.

 

4.

Remove any remaining piece of electrode from the

 

 

• Do not stack anything on or near

 

 

electrode holder.

 

 

 

 

 

 

 

 

the engine.

 

5.

If you are finished using the OUTBACK® 185 for

 

 

MOVING PARTS can injure.

 

welding, disconnect the welding cables from the weld

 

 

 

output terminals. Reattach the flange nuts and leave

 

 

Do not operate with doors open or

 

 

 

 

them on the terminals.

 

 

 

 

guards off.

 

 

 

 

 

For DC+ welding, the electrode cable is to be connected

 

 

Stop engine before servicing.

 

 

to the “+” output stud and work cable to the “-” output

 

 

• Keep away from moving parts.

stud. (For DC- welding, reverse these connections.)

Only qualified

personnel should install, use, or

Semi-automatic Wire Welding

with a Lincoln Wire

service this equipment.

Feeder/Welder

 

 

 

 

 

 

 

 

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The OUTBACK® 185 can deliver from 50 to 185 amps of welding output current . Output can be adjusted by setting the current control dial on the out- put control panel.

You can get maximum welding output by setting the dial to 185 AMPS. At high current settings like this, some output may decrease as the machine is used. If you are welding for a long time, you may need to turn the dial slightly upward to maintain the same results.

The numbers on the dial correspond to the approxi- mate amps needed to weld using specific Lincoln welding rods. Table B.2, WELDING APPLICATIONS, give you the recommended dial settings based on the thickness of the work and the size and type of rod you’re using.

TO USE THE OUTBACK® 185 FOR WELDING:

1.Remove the flange nuts from the weld output ter- minals and place the work and electrode welding cables over the terminals. See Figure B.1 and B.1a. Replace and tighten the flange nuts securely. Be sure the connections are tight.

2.Select the appropriate electrode. See Table B.2

3.Attach the work clamp securely to the work you are welding.

The OUTBACK® 185 generator power can be used to supply up to 5,200 watts continuous input power to a Lincoln Wire Feeder/Welder. The Wire Feeder/ Welder is equipped with all the supplies needed for Flux-Cored Arc Welding (FCAW). Also some Wire Feeder/Welders come equipped with the essentials needed for Gas Metal Arc Welding (GMAW) or MIG processes, while others require the purchase of a conversion kit. These products are available where Lincoln products are sold. Contact your local authorized Lincoln representative for more details.

Plasma Cutting with Lincoln Pro-Cut 25.

The OUTBACK® 185 generator power can be used to supply up to 5,200 watts continuous input power to a Pro- Cut 25. The Pro-Cut will work satisfactorily under the fol- lowing conditions:

1.Set the Current Control on the OUTBACK® 185 to the 185 amp position. (Higher Settings may result in a shutdown of the Pro-Cut 25.)

2.Leave the "ON/OFF" switch on the Pro-Cut "OFF" until the OUTBACK® 185 has been started and is at full operating speed.

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