Lincoln-electric OUTBACK SVM204-A User Manual

SVM204-AOctober, 2010Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However,you

INSTALLATIONA-2 A-2OUTBACK® 185TECHNICAL SPECIFICATIONS - OUTBACK® 185 (K2706-1)Make/Model Description Speed (RPM) Displacement Ignition CapacitiesSy

SAFETY PRECAUTIONSRead this entire installation section before youstart installation.Do not attempt to use this equipment until youhave

SPARK ARRESTERSome federal, state or local laws may require gasolineengines to be equipped with exhaust spark arresterswhen they are operated i

INSTALLATIONA-5 A-5OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

INSTALLATIONA-6 A-6OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

INSTALLATIONA-7 A-7OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

INSTALLATIONA-8 A-8OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

TABLE OF CONTENTS - OPERATION SECTIONB-1 B-1OUTBACK® 185Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATIONB-2 B-2OUTBACK® 185SAFETY INSTRUCTIONSObserve additional Safety Guidelines detailedthroughout this manual.WARNINGWARNINGENGINE EXHAUST ca

OPERATIONB-3 B-3OUTBACK® 185GRAPHIC SYMBOLS USED ON THIS EQUIPMENT OR IN THIS MANUALWARNING /CAUTIONCHOKEOILFUELAIR CLEANERCIRCUITBREAKERGROUND(AUXILI

OUTBACK® 185SAFETYi iFOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requi

OPERATIONB-4 B-4OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast

OPERATIONB-5 B-5OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast

OPERATIONB-6 B-6OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast

OPERATIONB-7 B-7OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast

OPERATIONB-8 B-8OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast

OPERATIONB-9 B-9OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast

NOTESB-10 B-10OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

TABLE OF CONTENTS - ACCESSORIES SECTIONC-1 C-1OUTBACK® 185Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIESC-2 C-2OUTBACK® 185OPTIONS/ACCESSORIESThe following options/accessories are available foryour OUTBACK®185 from your local LincolnD

TABLE OF CONTENTS - MAINTENANCE SECTIOND-1 D-1OUTBACK® 185Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETYii iiOUTBACK® 185FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing thesefumes a

MAINTENANCED-2 D-2OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

MAINTENANCED-3 D-3OUTBACK® 185SAFETY PRECAUTIONS• Have qualified personnel do all maintenance andtroubleshooting work. • Turn the engine o

To service the pre-cleaner: Remove the cover. Carefully remove the foam pre-cleaner from the filter element.1. Wash in liquid detergent and

MAINTENANCED-5 D-5OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Ma

NOTESD-6 D-6OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master T

TABLE OF CONTENTS-THEORY OF OPERATION SECTIONE-1 E-1OUTBACK® 185Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THEORY OF OPERATIONE-2 E-2OUTBACK® 185ENGINE STARTING, PROTECTIONAND BATTERY CHARGINGENGINE STARTINGA 12 Volt battery supplies power to the

THEORY OF OPERATIONE-3 E-3OUTBACK® 185ENGINE STARTING, PROTECTIONAND BATTERY CHARGING (contin-ued)BATTERY CHARGINGThe Kohler engine has a built-i

THEORY OF OPERATIONE-4 E-4OUTBACK® 185AUTOMATIC IDLE SYSTEMThe Outback® 185 is equipped with an automaticengine idle system. A solenoid

THEORY OF OPERATIONE-5 E-5OUTBACK® 185GENERATING POWERFlashingWhen the engine is running, power from the enginecharging system is stabilized,

OUTBACK® 185SAFETYiii iiiFOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe e

THEORY OF OPERATIONE-6 E-6OUTBACK® 185GENERATING POWER(continued)DC Weld OutputAC output from the two phase-shifted weld windingspass through a

TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIRF-1 F-1OUTBACK® 185Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING AND REPAIRF-2 F-2OUTBACK® 185This Troubleshooting Guide is provided tohelp you locate and repair possible machinemalfunctions.

TROUBLESHOOTING AND REPAIRF-3 F-3OUTBACK® 185Sometimes machine failures appear to be due to PCboard failures. These problems can sometimes

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

SAFETYiv ivOUTBACK® 185PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté spe

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

NOTESF-12 F-12OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

FAN BLADESTROBE-TACH MARKFIGURE F.1 – STROBE-TACH METHODENGINE RPM ADJUSTMENT PROCEDURE (continued)PROCEDUREStrobe-Tach Method1. Turn the engine off.

Low IdleJam NutsSwivelFitting Solenoid Rubber BootHigh IdleScrew & Jam NutEngine SpeedControl LeverEngineSolenoid & FuelPump BracketElectri

HIGH IDLE ADJUSTMENTLOW IDLE ADJUSTMENTTOP VIEW OF ENGINEFIGURE F.3 – VIBRATACH METHODENGINE RPM ADJUSTMENT PROCEDURE (continued)Vibratach MethodA Vi

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

HIGH IDLE ADJUSTMENTLOW IDLE ADJUSTMENTTOP VIEW OF ENGINEFIGURE F.4 – HIGH AND LOW IDLE ADJUSTMENTTHROTTLE ADJUSTMENT PROCEDURE (continued)PROCEDUREHi

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

OUTBACK® 185SAFETYElectromagnetic Compatibility (EMC)ConformanceProducts displaying the CE mark are in conformity with European Community Council Dire

GENERATOR END BRACKETBRUSH HOLDER ASSEMBLYCOVERSCREWS (2)LOCKING TABSFIGURE F.5 – BRUSH HOLDER ASSEMBLY LOCATIONBRUSH AND SLIP RING SERVICE PROCEDURE

CABLE TIEBRUSHESFIGURE F.6 – BRUSH REMOVAL AND REPLACEMENTBRUSH AND SLIP RING SERVICE PROCEDURE (continued)9. Check for evidence of sticking bru

NOTESF-22 F-22OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

+-BRUSHESSLIP RINGSFIGURE F.7 – BRUSH AND SLIP RING LOCATIONSROTOR FLASHING AND VOLTAGE TEST (continued)PROCEDURE1. Be certain the battery is full

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

+-BATTERYFIGURE F.8 – CHARGING SYSTEMBATTERY CHARGING SYSTEM TEST (continued)TROUBLESHOOTING AND REPAIRF-26 F-26OUTBACK® 185Return to Section TOC Retu

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

HIGH IDLE ADJUSTMENTLOW IDLE ADJUSTMENTTOP VIEW OF ENGINEFIGURE F.9 – HIGH AND LOW IDLE ADJUSTMENTSTATOR VOLTAGE TEST (continued)PROCEDURE1. Verify t

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

OUTBACK® 185SAFETYElectromagnetic Compatibility (EMC)The size of the surrounding area to be considered will depend on the structure of the building an

+-BRUSHESSLIP RINGSFIGURE F.10 – ROTOR RESISTANCEROTOR RESISTANCE AND GROUND TEST (STATIC) (continued)PROCEDURE1. Turn the engine off.2. Remove the

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

+-BRUSHESSLIP RINGSFIGURE F.11 – BRUSH AND SLIP RING LOCATIONSROTOR RESISTANCE AND GROUND TEST (DYNAMIC) (continued)PROCEDURENOTE: This test is perf

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

STATOR SHORT CIRCUIT AND GROUND TEST (continued)PROCEDURE1. Perform Case Cover Removal Procedure.2. Disconnect anything that may be connected tothe

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

HIGH IDLE ADJUSTMENTLOW IDLE ADJUSTMENTTOP VIEW OF ENGINEFIGURE F.12 – HIGH AND LOW IDLE ADJUSTMENTWELD BOOST SYSTEM TEST (continued)PROCEDURE1. Check

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

CASE SCREWSCASE SCREWSFIGURE F.13 – CASE COVER REMOVALCASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)PROCEDURE1. Using a 3/8” wrench, re

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -I IOUTBACK® 185PageSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3/8’ SCREWSFUEL TANK3/8’ SCREWSFUEL TANK ENCLOSUREFIGURE F.14 – FUEL TANK REMOVALFUEL TANK AND ENCLOSUREREMOVAL AND REPLACEMENT PROCEDURE (continued)T

+-BATTERYMOUNTING BRACKETFIGURE F.15 – BATTERY LOCATIONFUEL TANK AND ENCLOSUREREMOVAL AND REPLACEMENT PROCEDURE (continued)TROUBLESHOOTING AND REPAIRF

NOTESF-42 F-42OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

3/8’ SCREWSCONTROL BOXEND PANELFUEL TANKFIGURE F.16 – CONTROL BOX REMOVALCONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE (continued)PROCEDURE1. Perform

+-BATTERYMOUNTING BRACKETFIGURE F.17 – BATTERY LOCATIONCONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE (continued)TROUBLESHOOTING AND REPAIRF-45 F-45OUT

NOTESF-46 F-46OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

TOLERANCE RINGBRUSH ASSEMBLYBEARING BRACKET END COVERCAST END BRACKETHAMMER TAPPINGPOINTSFIGURE F.18 – STATOR REMOVALSTATOR REMOVAL AND REPLACEMENT PR

RUBBER ENGINE MOUNT“OTHER ENGINE MOUNTS NOTVISIBLE FROM THIS ANGLE”FIGURE F.19 – NUTS & RUBBER ENGINE MOUNTSSTATOR REMOVAL AND REPLACEMENT PROCEDU

TABLE OF CONTENTS - INSTALLATION SECTIONA-1 A-1OUTBACK® 185Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TOLERANCE RINGSTATORFIGURE F.20 – STATOR LOCATIONSTATOR REMOVAL AND REPLACEMENT PROCEDURE (continued)10. Check the air gap between the rotor an

Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result

THROUGH BOLTROTORFIGURE F.21 – ROTOR LOCATIONROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued)TROUBLESHOOTING AND REPAIRF-52 F-52OUTBACK® 185Return

RETEST AFTER REPAIRTROUBLESHOOTING AND REPAIRF-53 F-53OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section

NOTESF-54 F-54OUTBACK® 185Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master

TABLE OF CONTENTS - DIAGRAM SECTIONG-1 G-1OUTBACK® 185Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ElEcTrical DiaGramSG-2OUTBacK® 185WiriNG DiaGram - cOmplETE machiNE cODE 11516 (l13878)WORK+ELECTRODECHOKEL197+-ROTORFIELDSLIPRINGSOFFS1AUTOHIGH12345

ElEcTrical DiaGramSG-3OUTBacK® 185SchEmaTic - cOmplETE machiNE cODE 11516 (G6205)G6205OUTBACK 185MACHINE SCHEMATCNONE-DO NOTSCALETHIS DRAWINGEQUIPMEN

ElEcTrical DiaGramSG-4OUTBacK® 185SchEmaTic - FiElD cONTrOl / iDlE pc BOarD (G4793-1)G-4NOTE: This diagram is for reference only. It may not be accur