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Manual Lincoln Electric OUTBACK SVM204-A

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  • Lincoln Electric OUTBACK SVM204-A - page 1

    SVM204-A October , 2010 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by proper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PREC ...

  • Lincoln Electric OUTBACK SVM204-A - page 2

    OUTBACK® 185 SAFETY i i FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________ ...

  • Lincoln Electric OUTBACK SVM204-A - page 3

    SAFETY ii ii OUTBACK® 185 FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrodes which requi ...

  • Lincoln Electric OUTBACK SVM204-A - page 4

    OUTBACK® 185 SAFETY iii iii FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recommendations. 8.c. Ground the equipment in accordance with ...

  • Lincoln Electric OUTBACK SVM204-A - page 5

    SAFETY iv iv OUTBACK® 185 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a. ...

  • Lincoln Electric OUTBACK SVM204-A - page 6

    OUTBACK® 185 SAFETY Electromagnetic Compatibility (EMC) Confor mance P roducts displaying the CE mark are in conformit y with European Comm unity Council Directiv e of 1 5 Dec 2004 on the appro ximation of the laws of the Member States relating to electromagnetic compatibility , 2004/1 08/EC. It was manufactur ed in conformit y with a national sta ...

  • Lincoln Electric OUTBACK SVM204-A - page 7

    OUTBACK® 185 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area ma y ext end bey ond the boundar ies of the premises. Methods of Reducing Emissions Mains Supply W elding equipment should be connect ...

  • Lincoln Electric OUTBACK SVM204-A - page 8

    - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - I I OUTBACK® 185 Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Lincoln Electric OUTBACK SVM204-A - page 9

    T ABLE OF CONTENTS - INST ALLA TION SECTION A-1 A-1 OUTBACK® 185 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Lincoln Electric OUTBACK SVM204-A - page 10

    INST ALLA TION A-2 A-2 OUTBACK® 185 TECHNICAL SPECIFICA TIONS - OUTBACK® 185 (K2706-1) Make/Model Description Speed (RPM) Displacement Ignition Capacities System KOHLER 1 cylinder 3750RPM High Idle 21.96 cu. in Electric & Recoil Fuel: 6.86 gal. CS 12.75 4 cycle 1825RPM Low Idle (360 cc) Start; (24.9L) air-cooled 3400RPM Full Load OHV gasoline ...

  • Lincoln Electric OUTBACK SVM204-A - page 11

    SAFETY PRECAUTIONS Read this entire installation section before you start installation. Do not attempt to use this equipment until you have thoroughly read all operating and mainte- nance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. ...

  • Lincoln Electric OUTBACK SVM204-A - page 12

    SP ARK ARRESTER Some federal, state or local laws may require gasoline engines to be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard muffler included with this machine does not qualify as a spark arrester . For areas requiring spark arrestors, use K279 ...

  • Lincoln Electric OUTBACK SVM204-A - page 13

    INST ALLA TION A-5 A-5 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL OUTPUT CONNECTIONS See Figure A.1 for the location of the current control dial, weld output terminals, ground stud, circuit break- ...

  • Lincoln Electric OUTBACK SVM204-A - page 14

    INST ALLA TION A-6 A-6 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MACHINE GROUNDING Because this portable engine driven welder or genera- tor creates its own power , it is not necessary to connect its frame ...

  • Lincoln Electric OUTBACK SVM204-A - page 15

    INST ALLA TION A-7 A-7 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PREMISES WIRING The OUTBACK® 185 is not recommended for premis- es wiring. The OUTBACK® 185 does not have a com- bined 120/240 volt recepta ...

  • Lincoln Electric OUTBACK SVM204-A - page 16

    INST ALLA TION A-8 A-8 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CAUTION Certain Electrical devices cannot be powered by the OUTBACK® 185. See T able A.2 T ABLE A.2 ELECTRICAL DEVICE USE WITH THE OUTBACK® ...

  • Lincoln Electric OUTBACK SVM204-A - page 17

    T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 OUTBACK® 185 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Lincoln Electric OUTBACK SVM204-A - page 18

    OPERA TION B-2 B-2 OUTBACK® 185 SAFETY INSTRUCTIONS Observe additional Safety Guidelines detailed throughout this manual. W ARNING W ARNING ENGINE EXHAUST can kill. • Use in open, well ventilated areas or vent exhaust outside. • Do not stack anything on or near the engine. MOVING P ARTS can injure. • Do not operate with doors open or guards ...

  • Lincoln Electric OUTBACK SVM204-A - page 19

    OPERA TION B-3 B-3 OUTBACK® 185 GRAPHIC SYMBOLS USED ON THIS EQUIPMENT OR IN THIS MANUAL W ARNING / CAUTION CHOKE OIL FUEL AIR CLEANER CIRCUIT BREAKER GROUND (AUXILIAR Y POWER) WORK CLAMP ELECTRODE WELDING ARC F AST SLOW AUT O IDLE ENGINE OFF ENGINE ST ART Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Retu ...

  • Lincoln Electric OUTBACK SVM204-A - page 20

    OPERA TION B-4 B-4 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GENERAL DESCRIPTION The OUTBACK® 185 is designed for commercial use welder/generator applications. As a welder it provides 185 amps of DC consta ...

  • Lincoln Electric OUTBACK SVM204-A - page 21

    OPERA TION B-5 B-5 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1 2 7 8 3 or 4 6 9 10 12 1 1 5 CONTROLS AND SETTINGS All welder/generator controls are located on the Output Control Panel. Gasoline engine contr ...

  • Lincoln Electric OUTBACK SVM204-A - page 22

    OPERA TION B-6 B-6 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ENGINE OPERA TION Starting/Shutdown Instructions Be sure all Pre-Operation Engine Service has been performed. Also, Read owners manual before sta ...

  • Lincoln Electric OUTBACK SVM204-A - page 23

    OPERA TION B-7 B-7 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 4. Insert the electrode into the electrode hold er . 5. Set the current control dial to the desired output current . 6. Start the gasoline engine ...

  • Lincoln Electric OUTBACK SVM204-A - page 24

    OPERA TION B-8 B-8 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE B.2 ELECTRODE SELECTION GUIDE 120V Receptacle Operation: • Set the Output Control on the Pro-Cut 25 no higher than the 15 amp position.( ...

  • Lincoln Electric OUTBACK SVM204-A - page 25

    OPERA TION B-9 B-9 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE B.3 AUXILIAR Y POWER APPLICA TIONS Suggested Power Applications Running W atts *Start-up W atts ( Co nt in u ou s) ( P e ak ) *Air Compres ...

  • Lincoln Electric OUTBACK SVM204-A - page 26

    NOTES B-10 B-10 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric OUTBACK SVM204-A - page 27

    T ABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 OUTBACK® 185 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Options / Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Lincoln Electric OUTBACK SVM204-A - page 28

    ACCESSORIES C-2 C-2 OUTBACK® 185 OPTIONS/ACCESSORIES The following options/accessories are available for your OUTBACK®185 from your local Lincoln Distributor: Accessory Kit (K875) – Includes the following: • T wenty feet (6.1 meters) of #6 A WG electrode cable with lug. • Fifteen feet (4.6 meters) of #6 work cable with lugs. • Work Clamp ...

  • Lincoln Electric OUTBACK SVM204-A - page 29

    T ABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 OUTBACK® 185 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Lincoln Electric OUTBACK SVM204-A - page 30

    MAINTENANCE D-2 D-2 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric OUTBACK SVM204-A - page 31

    MAINTENANCE D-3 D-3 OUTBACK® 185 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the en gin e o ff be for e w ork in g in si de t he machine. • Remove guards only when necessary to perform maintenance and replace them when the mainte- nance requiring their removal is complete. • If guards a ...

  • Lincoln Electric OUTBACK SVM204-A - page 32

    T o service the pre-cleaner : Remove the cover . Carefully remove the foam pre- cleaner from the filter element. 1. W ash in liquid detergent and water . 2. Squeeze dry in a clean cloth. 3. Saturate in clean engine oil. 4. Squeeze in a clean, absorbent cloth to remove all excess oil. Carefully place the pre-cleaner back over the filter ele- ment an ...

  • Lincoln Electric OUTBACK SVM204-A - page 33

    MAINTENANCE D-5 D-5 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1. CRADLE ASBL Y , BA TTER Y & ROOF 2. CONTROL P ANEL ASSEMBL Y 3. ST A TOR & ROTOR ASSEMBL Y 4. REAR CONTROL P ANEL & FUEL T ANK AS ...

  • Lincoln Electric OUTBACK SVM204-A - page 34

    NOTES D-6 D-6 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric OUTBACK SVM204-A - page 35

    T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 OUTBACK® 185 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 Engine Starting, Protection and Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Lincoln Electric OUTBACK SVM204-A - page 36

    THEOR Y OF OPERA TION E-2 E-2 OUTBACK® 185 ENGINE ST ARTING, PROTECTION AND BA TTER Y CHARGING ENGINE ST ARTING A 12 V olt battery supplies power to the rotary run/stop/idle switch through a fuse that is located inside the control box. There is also a lead running from the fuse to the PC board. This is for battery charging only . When the switch i ...

  • Lincoln Electric OUTBACK SVM204-A - page 37

    THEOR Y OF OPERA TION E-3 E-3 OUTBACK® 185 ENGINE ST ARTING, PROTECTION AND BA TTER Y CHARGING (contin- ued) BA TTER Y CHARGING The Kohler engine has a built-in battery charging sys- tem. Output from the charging system is applied to the PC board where it is stabilized by the battery and then used to power the board electronics, the generator flas ...

  • Lincoln Electric OUTBACK SVM204-A - page 38

    THEOR Y OF OPERA TION E-4 E-4 OUTBACK® 185 AUT OMA TIC IDLE SYSTEM The Outback® 185 is equipped with an automatic engine idle system. A solenoid is used to pull the engine throttle to a preset low speed position when 12 volts DC is applied. When no voltage is applied, the solenoid is released allowing the engine governor to control the RPM. The ? ...

  • Lincoln Electric OUTBACK SVM204-A - page 39

    THEOR Y OF OPERA TION E-5 E-5 OUTBACK® 185 GENERA TING POWER Flashing When the engine is running, power from the engine charging system is stabilized, and then applied to the rotor brushes through a series of PC board mounted current limiting resistors and a “flashing” diode. Building Output The flashing current produces a weak magnetic field ...

  • Lincoln Electric OUTBACK SVM204-A - page 40

    THEOR Y OF OPERA TION E-6 E-6 OUTBACK® 185 GENERA TING POWER (continued) DC Weld Output AC output from the two phase-shifted weld windings pass through a reactor then to a two-phase bridge rec- tifier . DC output from the rectifier is then stabilized by a choke and terminates at two weld output terminals. Weld Output Control Weld output is control ...

  • Lincoln Electric OUTBACK SVM204-A - page 41

    T ABLE OF CONTENTS - TROUBLESHOOTING AND REP AIR F-1 F-1 OUTBACK® 185 T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use T roubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Lincoln Electric OUTBACK SVM204-A - page 42

    TROUBLESHOOTING AND REP AIR F-2 F-2 OUTBACK® 185 This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible symptoms that the m ...

  • Lincoln Electric OUTBACK SVM204-A - page 43

    TROUBLESHOOTING AND REP AIR F-3 F-3 OUTBACK® 185 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure: 1. Determine to the best of your technical ability that the ...

  • Lincoln Electric OUTBACK SVM204-A - page 44

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the test s/repairs safely , contact the Lincoln Electric Service Department for technical trouble ...

  • Lincoln Electric OUTBACK SVM204-A - page 45

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the test s/repairs safely , contact the Lincoln Electric Service Department for technical trouble ...

  • Lincoln Electric OUTBACK SVM204-A - page 46

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the t est procedures or are unable to perform the t ests/repairs safely , contact the Lincoln Electric Service Department for technical troubl ...

  • Lincoln Electric OUTBACK SVM204-A - page 47

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the t est procedures or are unable to perform the t ests/repairs safely , contact the Lincoln Electric Service Department for technical troubl ...

  • Lincoln Electric OUTBACK SVM204-A - page 48

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the test s/repairs safely , contact the Lincoln Electric Service Department for technical trouble ...

  • Lincoln Electric OUTBACK SVM204-A - page 49

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the test s/repairs safely , contact the Lincoln Electric Service Department for technical trouble ...

  • Lincoln Electric OUTBACK SVM204-A - page 50

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the test s/repairs safely , contact the Lincoln Electric Service Department for technical trouble ...

  • Lincoln Electric OUTBACK SVM204-A - page 51

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the t est procedures or are unable to perform the t ests/repairs safely , contact the Lincoln Electric Service Department for technical troubl ...

  • Lincoln Electric OUTBACK SVM204-A - page 52

    NOTES F-12 F-12 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric OUTBACK SVM204-A - page 53

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr ...

  • Lincoln Electric OUTBACK SVM204-A - page 54

    F AN BLADE STROBE-T ACH MARK FIGURE F .1 – STROBE-T ACH METHOD ENGINE RPM ADJUSTMENT PROCEDURE (continued) PROCEDURE Strobe-T ach Method 1. T urn the engine off. 2. Place a highly visible mark on a component that rotates while the engine is running. The rotor- cooling fan is a good place for this mark. See Figure F .1. 3. Connect the strobe-tach ...

  • Lincoln Electric OUTBACK SVM204-A - page 55

    Low Idle Jam Nuts Swivel Fitting Solenoid Rubber Boot High Idle Screw & Jam Nut Engine Speed Control Lever Engine Solenoid & Fuel Pump Bracket Electric Fuel Pump (codes 10926 &11121 only) INCREASE (RPM) DECREASE (RPM) MOVING ENGINE SPEED CONTROL LEVER FIGURE F .2 – FREQUENCY COUNTER METHOD ENGINE RPM ADJUSTMENT PROCEDURE (continued) F ...

  • Lincoln Electric OUTBACK SVM204-A - page 56

    HIGH IDLE ADJUSTMENT L OW IDLE ADJUSTMENT T OP VIEW OF ENGINE FIGURE F .3 – VIBRA T ACH METHOD ENGINE RPM ADJUSTMENT PROCEDURE (continued) Vibratach Method A Vibratach is used to measure the vibrations caused by the running engine. It can be positioned anywhere where the engine vibration is reasonably strong. 1. Read and understand the manufactur ...

  • Lincoln Electric OUTBACK SVM204-A - page 57

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr ...

  • Lincoln Electric OUTBACK SVM204-A - page 58

    HIGH IDLE ADJUSTMENT L OW IDLE ADJUSTMENT T OP VIEW OF ENGINE FIGURE F .4 – HIGH AND LOW IDLE ADJUSTMENT THROTTLE ADJUSTMENT PROCEDURE (continued) PROCEDURE High Idle Adjustment Check that the linkage attaching the solenoid to the engine speed control lever is in good condition and moves freely . 1. Start the engine and place the engine switch in ...

  • Lincoln Electric OUTBACK SVM204-A - page 59

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr ...

  • Lincoln Electric OUTBACK SVM204-A - page 60

    GENERA TOR END BRACKET BRUSH HOLDER ASSEMBL Y COVER SCREWS (2) LOCKING T ABS FIGURE F .5 – BRUSH HOLDER ASSEMBL Y LOCA TION BRUSH AND SLIP RING SERVICE PROCEDURE (continued) PROCEDURE 1. Remove the brush cover from the end of the generator . 2. Pry outward at the top of the plastic brush cover while depressing the two locking tabs at the sides of ...

  • Lincoln Electric OUTBACK SVM204-A - page 61

    CABLE TIE BRUSHES FIGURE F .6 – BRUSH REMOV AL AND REPLACEMENT BRUSH AND SLIP RING SERVICE PROCEDURE (continued) 9. Check for evidence of sticking brushes. Sticking brushes will normally result in the slip rings being pitted and discolored from exces- sive arcing. Another sign of sticking brushes is instability or loss of both weld and auxiliary ...

  • Lincoln Electric OUTBACK SVM204-A - page 62

    NOTES F-22 F-22 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric OUTBACK SVM204-A - page 63

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr ...

  • Lincoln Electric OUTBACK SVM204-A - page 64

    + - BRUSHES SLIP RINGS FIGURE F .7 – BRUSH AND SLIP RING LOCA TIONS ROT OR FLASHING AND VOL T AGE TEST (continued) PROCEDURE 1. Be certain the battery is fully charged and the battery charging system is functioning normally . 2. Ensure that there is no load on either the weld or auxiliary outputs. 3. Set the output control to maximum. 4. Remove t ...

  • Lincoln Electric OUTBACK SVM204-A - page 65

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr ...

  • Lincoln Electric OUTBACK SVM204-A - page 66

    + - BA TTER Y FIGURE F .8 – CHARGING SYSTEM BA TTER Y CHARGING SYSTEM TEST (continued) TROUBLESHOOTING AND REP AIR F-26 F-26 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PROCEDURE DO NOT REMOVE BA TTERY CABL ...

  • Lincoln Electric OUTBACK SVM204-A - page 67

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr ...

  • Lincoln Electric OUTBACK SVM204-A - page 68

    HIGH IDLE ADJUSTMENT L OW IDLE ADJUSTMENT T OP VIEW OF ENGINE FIGURE F .9 – HIGH AND LOW IDLE ADJUSTMENT ST A TOR VOL T AGE TEST (continued) PROCEDURE 1. V erify that the engine RPM is normal. See the Engine RPM Adjustment Procedure . 2. Start the machine and place the idle switch in the high position. See Figure F .9. 3. Check for AC voltage bet ...

  • Lincoln Electric OUTBACK SVM204-A - page 69

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr ...

  • Lincoln Electric OUTBACK SVM204-A - page 70

    + - BRUSHES SLIP RINGS FIGURE F .10 – ROTOR RESIST ANCE ROT OR RESIST ANCE AND GROUND TEST (ST A TIC) (continued) PROCEDURE 1. Turn the engine off. 2. Remove the plastic cover from the end of the generator . See Brush and Slip Ring Service Procedure . 3. Using needle-nose pliers, remove the leads from the brush terminals. This will electrically i ...

  • Lincoln Electric OUTBACK SVM204-A - page 71

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr ...

  • Lincoln Electric OUTBACK SVM204-A - page 72

    + - BRUSHES SLIP RINGS FIGURE F .1 1 – BRUSH AND SLIP RING LOCA TIONS ROT OR RESIST ANCE AND GROUND TEST (DYNAMIC) (continued) PROCEDURE NOTE: This test is performed using a good quali- ty analog type ohmmeter . Many digital meters will not provide stable or accurate resistance readings while the rotor is spin- ning. 1. This test requires that th ...

  • Lincoln Electric OUTBACK SVM204-A - page 73

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr ...

  • Lincoln Electric OUTBACK SVM204-A - page 74

    ST A TOR SHORT CIRCUIT AND GROUND TEST (continued) PROCEDURE 1. Perform Case Cover Removal Procedure . 2. Disconnect anything that may be connected to the auxiliary receptacles or the weld output ter- minals. 3. Disconnect and isolate GND-C lead from the ground stud on the control panel front. See wiring diagram. 4. Disconnect and isolate lead #5 f ...

  • Lincoln Electric OUTBACK SVM204-A - page 75

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr ...

  • Lincoln Electric OUTBACK SVM204-A - page 76

    HIGH IDLE ADJUSTMENT L OW IDLE ADJUSTMENT T OP VIEW OF ENGINE FIGURE F .12 – HIGH AND LOW IDLE ADJUSTMENT WELD BOOST SYSTEM TEST (continued) PROCEDURE 1. Check that the CB4 circuit breaker is not tripped. 2. Check that the battery is fully charged and in good condition. 3. Set the output dial to the Maximum position. 4. Start the engine and place ...

  • Lincoln Electric OUTBACK SVM204-A - page 77

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr ...

  • Lincoln Electric OUTBACK SVM204-A - page 78

    CASE SCREWS CASE SCREWS FIGURE F .13 – CASE COVER REMOV AL CASE COVER REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Using a 3/8” wrench, remove all screws from the top of the red sheet metal cover . 2. Lift the top cover of f of the machine 3. T o replace the cover , reverse the above proce- dure. TROUBLESHOOTING AND REP AIR F-38 ...

  • Lincoln Electric OUTBACK SVM204-A - page 79

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr ...

  • Lincoln Electric OUTBACK SVM204-A - page 80

    3/8’ SCREWS FUEL T ANK 3/8’ SCREWS FUEL T ANK ENCLOSURE FIGURE F .14 – FUEL T ANK REMOV AL FUEL T ANK AND ENCLOSURE REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-40 F-40 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric OUTBACK SVM204-A - page 81

    + - BA TTERY MOUNTING BRACKET FIGURE F .15 – BA TTER Y LOCA TION FUEL T ANK AND ENCLOSURE REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-41 F-41 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return t ...

  • Lincoln Electric OUTBACK SVM204-A - page 82

    NOTES F-42 F-42 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric OUTBACK SVM204-A - page 83

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr ...

  • Lincoln Electric OUTBACK SVM204-A - page 84

    3/8’ SCREWS CONTROL BOX END P ANEL FUEL T ANK FIGURE F .16 – CONTROL BOX REMOV AL CONTROL BOX REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Perform the Case Cover Removal Procedure. 2. Using the 7/16” wrench, loosen battery mount- ing bracket. See Figure F .16. 3. Remove the battery . 4. Perform the Fuel T ank and Enclosure Remo ...

  • Lincoln Electric OUTBACK SVM204-A - page 85

    + - BA TTER Y MOUNTING BRACKET FIGURE F .17 – BA TTER Y LOCA TION CONTROL BOX REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-45 F-45 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric OUTBACK SVM204-A - page 86

    NOTES F-46 F-46 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric OUTBACK SVM204-A - page 87

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr ...

  • Lincoln Electric OUTBACK SVM204-A - page 88

    TOLERANCE RING BRUSH ASSEMBL Y BEARING BRACKET END COVER CAST END BRACKET HAMMER T APPING POINTS FIGURE F .18 – ST A TOR REMOV AL ST A TOR REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Perform the Control Box Removal Procedure . 2. Remove the brushes. See the Brush and Slip Ring Service Procedure . 3. Label and disconnect any wiring ...

  • Lincoln Electric OUTBACK SVM204-A - page 89

    RUBBER ENGINE MOUNT “ OTHER ENGINE MOUNTS NOT VISIBLE FROM THIS ANGLE ” FIGURE F .19 – NUTS & RUBBER ENGINE MOUNTS ST A TOR REMOV AL AND REPLACEMENT PROCEDURE (continued) Installing the stator assembly: 1. If the rotor has been removed, it must be replaced before installation of the stator assem- bly . See the Rotor Removal Procedure. Imp ...

  • Lincoln Electric OUTBACK SVM204-A - page 90

    TOLERANCE RING ST A TOR FIGURE F .20 – ST A TOR LOCA TION ST A TOR REMOV AL AND REPLACEMENT PROCEDURE (continued) 10. Check the air gap between the rotor and the stator . Feeler gages are inserted between the rotor and stator through the brush access opening. A .010 gage should be able to pass completely through the air gap and a .030 gage should ...

  • Lincoln Electric OUTBACK SVM204-A - page 91

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr ...

  • Lincoln Electric OUTBACK SVM204-A - page 92

    THROUGH BOL T ROT OR FIGURE F .21 – ROTOR LOCA TION ROT OR REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-52 F-52 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PROCEDURE 1. Perfo ...

  • Lincoln Electric OUTBACK SVM204-A - page 93

    RETEST AFTER REP AIR TROUBLESHOOTING AND REP AIR F-53 F-53 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PROCEDURE No-load test values High idle (No load) RPM: 3700-3800 RPM (61.7 – 63.3 Hz) Low idle RPM: 225 ...

  • Lincoln Electric OUTBACK SVM204-A - page 94

    NOTES F-54 F-54 OUTBACK® 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

  • Lincoln Electric OUTBACK SVM204-A - page 95

    T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 OUTBACK® 185 Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram - Complete Machine Code 1 1516 (L13878) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2 ...

  • Lincoln Electric OUTBACK SVM204-A - page 96

    ElEcTrical DiaGramS G-2 OUTBacK® 185 WiriNG DiaGram - cOmplETE machiNE cODE 1 1516 (l13878) WOR K + ELE CT RODE CHOKE L1 9 7 + - R OT OR FIEL D SLIP RIN GS OF F S1 A UT O HIG H 1 2 3 4 5 6 ST A RT ER S OL EN OID EN GIN E ST A RT ER FU S E 230 OIL LE V EL MO D UL E BL UE BL ACK BL ACK BW BW YY BR BR B IDLE S OL E N OID ALT. IGNITI ON C OIL S SPARK ...

  • Lincoln Electric OUTBACK SVM204-A - page 97

    ElEcTrical DiaGramS G-3 OUTBacK® 185 SchEma Tic - cOmplETE machiNE cODE 1 1516 (G6205) G6205 O UTBA C K 18 5 MAC HI N E SC HEM ATC NONE - DO NO T SC AL E T HIS DR A WING EQ UIP M ENT TYPE: SUBJECT: SCA L E: UF CRM40758 1 PAGE ___ OF ___ 1 E NGI N EE RI NG CO NT RO LLE D MA NU FA CT URE R: No THIS DOCUMENT CONTAINS PROPRIETAR Y INFORMATION OWNED B ...

  • Lincoln Electric OUTBACK SVM204-A - page 98

    ElEcTrical DiaGramS G-4 OUTBacK® 185 SchEma Tic - FiElD cONTrOl / iDlE pc BOarD (G4793-1) G-4 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master T ...

Manufacturer Lincoln Electric Category Welder

Documents that we receive from a manufacturer of a Lincoln Electric OUTBACK SVM204-A can be divided into several groups. They are, among others:
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All of them are important, but the most important information from the point of view of use of the device are in the user manual Lincoln Electric OUTBACK SVM204-A.

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals Lincoln Electric OUTBACK SVM204-A, service manual, brief instructions and user manuals Lincoln Electric OUTBACK SVM204-A. Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product Lincoln Electric OUTBACK SVM204-A.

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A complete manual for the device Lincoln Electric OUTBACK SVM204-A, how should it look like?
A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Lincoln Electric OUTBACK SVM204-A by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Lincoln Electric OUTBACK SVM204-A.

A complete Lincoln Electric manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual Lincoln Electric OUTBACK SVM204-A - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the Lincoln Electric OUTBACK SVM204-A, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the Lincoln Electric OUTBACK SVM204-A, that we can find in the current document
3. Tips how to use the basic functions of the device Lincoln Electric OUTBACK SVM204-A - which should help us in our first steps of using Lincoln Electric OUTBACK SVM204-A
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with Lincoln Electric OUTBACK SVM204-A
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of Lincoln Electric OUTBACK SVM204-A in a specific country, if it was not possible to solve the problem on our own.

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