Lincoln Electric SVM204-A Safety Precautions, Tighten dipstick firmly before starting

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D-3

MAINTENANCE

D-3

 

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SAFETY PRECAUTIONS

WARNING

Have qualified personnel do all maintenance and troubleshooting work.

Turn the engine off before working inside the machine.

Remove guards only when necessary to perform maintenance and replace them when the mainte- nance requiring their removal is complete.

If guards are missing from the machine, get replace- ments from a Lincoln Distributor. See the EXPLOD- ED VIEW AND PARTS LIST at the back of this man- ual.

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Read the Safety Precautions in the front of this manu- al and in the Kohler Operating and Maintenance Instructions manual before working on the OUT- BACK®185 Keep all equipment safety guards, covers, and devices in position and in good repair. Keep your hands, hair, clothing, and tools away from the recoil housing, fans, and all other moving parts when start- ing, operating, or repairing this machine.

OIL: Check the oil level after every 5 hours of operation or daily. BE SURE TO MAINTAIN THE OIL LEVEL.

Change the oil the first time after 20 hours of opera- tion. Then, under normal operating conditions, change the oil after every 100 hours or once a year, whichev- er occurs first. If the engine is operated under heavy load or in high ambient temperatures, change the oil every 50 hours.

Drain the oil from the drain plug located on either side of the engine bottom, as shown in Figure D.1. Refill through the oil fill plug until the oil reaches the full mark on the dip stick. See Engine Owner’s manual for spe- cific oil recommendations.

FIGURE D.1 - OIL DRAIN AND

REFILL LOCATION

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ROUTINE AND PERIODIC MAINTENANCE

Do not screw in

FILL to FULL mark on

dipstick to check oil

dipstick - recheck

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ENGINE MAINTENANCE

CAUTION

To prevent the engine from accidentally starting, dis- connect the spark plug lead before servicing the engine.

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Tighten dipstick firmly before starting

12 mm

HEX

Drain

plug

OIL DRAIN

PLUG

Oil drain

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See the Kohler Owner’s manual for a summary of maintenance intervals for the engine. Follow either the hourly or the calendar intervals, whichever come first. More frequent service may be required, depending on your specific application and operating conditions. The Kohler Owner’s manual shows engine maintenance replacement parts and numbers.

FUEL: At the end of each day’s use, refill the fuel tank to minimize moisture conden- sation and dirt contamination in the fuel line.

AIR CLEANER: With normal operating conditions, the maintenance schedule for cleaning and re-oiling the foam pre-filter is every 50 hours and replacement of the air cleaner filter element every 100 hours.

More frequent servicing is required with dusty operat- ing conditions. Refer to the maintenance section of the Engine Owner’s Manual for more information.

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 PowerLocation and Ventilation Safety PrecautionsStoring 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 SystemFlashing Generating PowerBuilding Output AC Output Weld Boost Generating PowerDC Weld Output Weld Output Control1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide Troubleshooting and RepairLocate PROBLEM SYMPTOM PC Board Troubleshooting Procedures Engine shut down function DisconnectingThis plug disables the normal Engine switchTroubleshooting and Repair Problems Symptoms Procedure Engine RPM adjustmentAdjustment procedure Troubleshooting and Repair Tests Perform the stator resistance Voltage tests Voltage, and resistanceEngine Brush and slip ring serviceBrush and slip Ring Service procedureCircuit 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 High Idle Adjustment Throttle Adjustment ProcedureLow 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 Perform the Case Cover Removal Procedure Removal and Replacement 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 Perform the Stator Removal Procedure Rotor Removal and Replacement ProcedureReplacing the Rotor 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