Lincoln Electric SVM204-A

TABLE OF CONTENTS - ACCESSORIES SECTION

C-1 C-1

OUTBACK® 185

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

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Contents

Main SVM204-A October, 2010 SERVICE MANUAL OUTBACK185 i i FOR ENGINE powered equipment. WARNING ELECTRIC AND MAGNETIC FIELDS may be dangerous ii ii FUMES AND GASES can be dangerous. ARC RAYS can burn. ELECTRIC SHOCK can kill. iii iii FOR ELECTRICALLY powered equipment. CYLINDER may explode if damaged. WELDING and CUTTING SPARKS can cause fire or explosion. Refer to http://www.lincolnelectric.com/safety for additional safety information. iv iv PRCAUTIONS DE SRET PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Page Electromagnetic Compatibility (EMC) - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - TABLE OF CONTENTS - INSTALLATION SECTION TECHNICAL SPECIFICATIONS - OUTBACK 185 (K2706-1) OPERATINGTEMPERATURE RANGE STORAGE TEMPERATURE RANGE INPUT - GASOLINE ENGINE RATED OUTPUT - WELDER SAFETY PRECAUTIONS Hazards of Electric Shock, Engine Exhaust & Moving Parts LOCATION AND VENTILATION STORING SPARK ARRESTER PRE-OPERATION ENGINE SERVICE OIL FUEL STACKING ELECTRICAL OUTPUT CONNECTIONS WELDING CABLE CONNECTIONS TABLE A.1 RECOMMENDED WELDING CABLE SIZE AND LENGTH OUTBACK 185 OUTPUT CONNECTIONS MACHINE GROUNDING PREMISES WIRING CIRCUIT BREAKERS PLUGS AND HAND HELD EQUIPMENT AUXILIARY POWER RECEPTACLES Page TABLE OF CONTENTS - OPERATION SECTION SAFETY INSTRUCTIONS WARNING WARNING Page GENERAL DESCRIPTION RECOMMENDED APPLICATIONS Welder Generator OPERATIONAL FEATURES AND CONTROLS WELDER/GENERATOR CONTROLS OUTPUT PANEL CONTROLS ENGINE OPERATION Starting/Shutdown Instructions Break-in Period Low Oil Sensing Typical Fuel Consumption WELDING OPERATION AUXILIARY POWER OPERATION GENERAL INFORMATION Page Page Page ACCESSORIES OPTIONS/ACCESSORIES TABLE OF CONTENTS - MAINTENANCE SECTION Page SAFETY PRECAUTIONS ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE FIGURE D.1 - OIL DRAIN AND REFILL LOCATION Do not screw in dipstick to check oil SPARK PLUG SERVICE ENGINE ADJUSTMENTS ENGINE MAINTENANCE PARTS OPERATIONAL CLEARANCE SLIP RINGS Page Page TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1 E-1 ENGINE _+ + ENGINE STARTING, PROTECTION AND BATTERY CHARGING ENGINE STARTING, PROTECTION AND BATTERY CHARGING (contin- ued) AUTOMATIC IDLE SYSTEM GENERATING POWER GENERATING POWER (continued) TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE PC BOARD TROUBLESHOOTING PROCEDURES Page Page Page Page Page Page Page Page Page ENGINE RPM ADJUSTMENT PROCEDURE Page Engine Speed Control Lever Engine Solenoid & Fuel Pump Bracket Electric Fuel Pump Page THROTTLE ADJUSTMENT PROCEDURE THROTTLE ADJUSTMENT PROCEDURE (continued) BRUSH AND SLIP RING SERVICE PROCEDURE PROCEDURE DESCRIPTION Page BRUSH AND SLIP RING SERVICE PROCEDURE (continued) Page ROTOR FLASHING AND VOLTAGE TEST + - SLIP RINGS BRUSHES ROTOR FLASHING AND VOLTAGE TEST (continued) BATTERY CHARGING SYSTEM TEST - BATTERY CHARGING SYSTEM TEST (continued) BATTERY + STATOR VOLTAGE TEST STATOR VOLTAGE TEST (continued) ROTOR RESISTANCE AND GROUND TEST (STATIC) + - SLIP RINGS BRUSHES ROTOR RESISTANCE AND GROUND TEST (STATIC) (continued) ROTOR RESISTANCE AND GROUND TEST (DYNAMIC) + - SLIP RINGS BRUSHES ROTOR RESISTANCE AND GROUND TEST (DYNAMIC) (continued) STATOR SHORT CIRCUIT AND GROUND TEST STATOR SHORT CIRCUIT AND GROUND TEST (continued) WELD BOOST SYSTEM TEST TOP VIEW OF ENGINE WELD BOOST SYSTEM TEST (continued) CASE COVER REMOVAL AND REPLACEMENT PROCEDURE CASE SCREWS CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) FUEL TANK AND ENCLOSURE REMOVAL AND REPLACEMENT PROCEDURE 3/8 SCREWS FUEL TANK 3/8 SCREWS FUEL TANK ENCLOSURE FUEL TANK AND ENCLOSURE REMOVAL AND REPLACEMENT PROCEDURE (continued) + - Page CONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE 3/8 SCREWS CONTROL BOX END PANEL FUEL TANK CONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE (continued) + - CONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE (continued) Page STATOR REMOVAL AND REPLACEMENT PROCEDURE DESCRIPTION TOLERANCE RING BRUSH ASSEMBLY CAST END BRACKET BEARING BRACKET END COVER HAMMER TAPPING POINTS Page TOLERANCE RING STATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE DESCRIPTION THROUGH BOLT ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) IMPORTANT ROTOR RETEST AFTER REPAIR Page TABLE OF CONTENTS - DIAGRAM SECTION * NOTE: ElEcTrical DiaGramS WiriNG DiaGram - cOmplETE machiNE cODE 11516 (l13878) Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC WIRI NG DI AGRAM - O UTB ACK 18 5 G-2 ElEcTrical DiaGramS SchEmaTic - cOmplETE machiNE cODE 11516 (G6205) Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC 12 11