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Lincoln Electric
SVM204-A
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NOTES
D-6 D-6
OUTBACKĀ® 185
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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)
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WIRI NG DI AGRAM - O UTB ACK 18 5
G-2
ElEcTrical DiaGramS
SchEmaTic - cOmplETE machiNE cODE 11516 (G6205)
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