Lincoln Electric SVM204-A service manual Outback

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OUTBACK® 185

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Contents Outback Safety California Proposition 65 WarningsElectric Shock can kill ARC Rays can burn Can be dangerousCylinder may explode Powered equipmentWelding Cutting Sparks can cause fire or If damaged ExplosionPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcSafety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section AC Auxiliary Power InstallationTechnical Specifications Outback 185 K2706-1 Bore x StrokeLocation and Ventilation Safety PrecautionsStoring Tilting PRE-OPERATION Engine ServiceStacking OILCable Size and Length Cable Amps Length 30% Duty CycleCable Installation Machine GroundingCircuit Breakers Auxiliary Power ReceptaclesPremises Wiring See Figure A.1Table A.2 Electrical Device USE with the Outback Type Common Electrical Devices Possible ConcernsTable of Contents Operation Section Safety Instructions OperationWork Clamp Ground Auxiliary Power Graphic Symbols Used on this Equipment or in this ManualOIL AIR Cleaner Fuel BreakerGeneral Description Design Features AdvantagesOperational Features and Controls Recommended ApplicationsWhen in Auto Idle WELDER/GENERATOR ControlsEngine Operation Stopping the EngineService this equipment Only qualified Personnel should install, use, orWith a Lincoln Wire Electric Shock can kill120V Receptacle Operation 240V Receptacle OperationTable B.3 Auxiliary Power Applications Outback Table of Contents Accessories Section Accessories OPTIONS/ACCESSORIESTable of Contents Maintenance Section Maintenance Safety Precautions Tighten dipstick firmly before startingTo service the pre-cleaner Kohler CSMaintenance Outback 1TABLE of CONTENTS-THEORY of Operation Section E-1 Engine STARTING, Protection and Battery Charging Theory of OperationEngine STARTING, Protection and Battery Charging contin- ued Automatic Idle System Figure E.4 Automatic Idle SystemFlashing Generating PowerBuilding Output AC Output Weld Output Control Generating PowerDC Weld Output Weld Boost1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide Troubleshooting and RepairLocate PROBLEM SYMPTOM PC Board Troubleshooting Procedures Engine switch DisconnectingThis plug disables the normal Engine shut down functionTroubleshooting and Repair Problems Symptoms Procedure Engine RPM adjustmentAdjustment procedure Troubleshooting and Repair Voltage, and resistance Tests Perform the stator resistance Voltage testsBrush and slip ring service EngineBrush and slip Ring Service procedureCircuit tests Outback Engine RPM Adjustment Procedure Test DescriptionEngine RPM Adjustment Procedure Strobe-Tach MethodControl Lever Frequency Counter MethodTOP View of Engine Vibratach MethodThrottle Adjustment Procedure High Idle Adjustment Throttle Adjustment ProcedureLow Idle Adjustment Brush and Slip Ring Service Procedure Procedure DescriptionBrush and Slip Ring Service Procedure Figure F.5 Brush Holder Assembly LocationCleaning Slip Rings Cable TIE BrushesOutback Rotor Flashing and Voltage Test Set the output control to maximum Battery Charging System Test Figure F.8 Charging System Stator Voltage Test Figure F.9 High and LOW Idle Adjustment Stator Voltage TestRotor Resistance and Ground Test Static Slip Rings Brushes Rotor Resistance and Ground Test StaticRotor Resistance and Ground Test Dynamic Rotor Resistance and Ground Test Dynamic Figure F.11 Brush and Slip Ring LocationsStator Short Circuit and Ground Test Perform Case Cover Removal Procedure Stator Short Circuit and Ground TestWeld Boost System Test Figure F.12 High and LOW Idle Adjustment Weld Boost System TestCase Cover Removal and Replacement Procedure Case Cover Removal and Replacement Procedure Figure F.13 Case Cover Removal Fuel 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 Control BOX Removal and Replacement Procedure Perform the Fuel Tank and Enclosure Removl ProcedureMounting Bracket Battery Outback Stator Removal and Replacement Procedure Stator Removal and Replacement Procedure Perform the Control Box Removal ProcedureInstalling the stator assembly Figure F.19 Nuts & Rubber Engine MountsTolerance Ring Stator Rotor Removal and Replacement Procedure Perform the Stator Removal Procedure Rotor Removal and Replacement ProcedureReplacing the Rotor Full load test values Retest After RepairNo-load test values Volt receptaclesOutback Table of Contents Diagram Section Wiring Diagram Outback OUTBacKSchEmaTic cOmplETE machiNE cODE 11516 G6205 Equipmenttype