Lincoln Electric OUTBACK SVM204-A Service Manual
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Lincoln Electric OUTBACK SVM204-A Service Manual

Lincoln Electric OUTBACK SVM204-A Service Manual

Lincoln electric welder user manual
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RETURN TO MAIN MENU
SVM204-A
October, 2010
OUTBACK 185
11516
For use with machine code number:
Safety Depends on You
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 INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT.
And,
most importantly, think before you
act and be careful.

SERVICE MANUAL

Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 1.888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Summary of Contents for Lincoln Electric OUTBACK SVM204-A

  • Page 1: Service Manual

    RETURN TO MAIN MENU SVM204-A October, 2010 OUTBACK 185 11516 For use with machine code number: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety increased by proper installation .

  • Page 2: California Proposition 65 Warnings

    Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
  • Page 4 WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area.If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjcent areas.
  • Page 5 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.
  • Page 6 SAFETY Electromagnetic Compatibility (EMC) Conformance Introduction Installation and Use Assessment of Area OUTBACK® 185...
  • Page 7 SAFETY Electromagnetic Compatibility (EMC) Methods of Reducing Emissions Mains Supply Maintenance of the Welding Equipment Welding Cables Equipotential Bonding Earthing of the Workpiece Screening and Shielding OUTBACK® 185...
  • Page 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN MENU Page Safety ................i-vi Installation .

  • Page 9: Table Of Contents

    TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .
  • Page 10 4 cycle air-cooled OHV gasoline 12.75 HP @ 3600 RPM Aluminum Block w/ Cast Iron Sleeve AMPS @ DC CONSTANT CURRENT OUTPUT -WELDER AND GENERATOR Welding Ranges 50 - 185 Amps DC HEIGHT WIDTH 25.47 in. 21.12 in. 646.94 mm 536.45 mm...

  • Page 11: Installation

    SAFETY PRECAUTIONS Read this entire installation section before you start installation. WARNING 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.

  • Page 12: Stacking

    STACKING OUTBACK® 185 machines CANNOT be stacked. TILTING Place the machine on a secure, level surface whenev- er you use it or store it. Any surfaces you place it on other than the ground must be firm, non-skid, and structurally sound. The gasoline engine is designed to run in a level posi- tion for best performance.

  • Page 13: Electrical Output Connections

    Be sure to use welding cables that are large enough. The correct size and length becomes especially impor- tant when you are welding at a distance from the welder. Table A.1 lists recommended cable sizes and lengths for rated current and duty cycle. Length refers to the dis- tance from the welder to the work and back to the welder.

  • Page 14: Machine Grounding

    • Do not cross welding cables at output stud connec- tion. Keep isolated and separate from one another. ------------------------------------------------------------------------ Lincoln Electric offers a welding accessory kit with #6 welding cables. See the ACCESSORIES section of this manual for more information.

  • Page 15: Premises Wiring

    PLUGS AND HAND HELD EQUIPMENT For further protection against electric shock, any elec- trical equipment connected to the generator recepta- cles must use a three-blade, grounded type plug or an Underwriter’s Laboratories (UL) approved double insu- lated tool with a two blade plug. WARNING Never operate this machine with damaged or defective cords.
  • Page 16 Capacitive / Inductive Computers, high resolution TV sets, complicated electrical equipment. The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to a OUTBACK® 185. INSTALLATION CAUTION TABLE A.2 Possible Concerns...
  • Page 17 Welder/Generator Controls ........

  • Page 18: Operation

    SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. •...
  • Page 19 GRAPHIC SYMBOLS USED ON THIS EQUIPMENT OR IN THIS MANUAL WARNING / CAUTION FUEL WORK CLAMP FAST SLOW AUTO IDLE OPERATION OUTBACK® 185 CHOKE AIR CLEANER CIRCUIT BREAKER GROUND (AUXILIARY POWER) ELECTRODE WELDING ARC ENGINE OFF ENGINE START...

  • Page 20: General Description

    The OUTBACK® 185 rated 185 amps, 20 VDC at 10% duty cycle on a ten-minute basis. This means that you can load the welder to 185 amps for one minute out of every ten-minute period. The machine is capable of higher duty cycles at lower output currents.

  • Page 21: Controls And Settings

    9. 120 VOLT DUPLEX RECEPTACLES (2): Connection point for supplying 120 volt power to operate devices needed for maintenance purposes. OPERATION All welder/generator controls are located on the Output Control Panel. Gasoline OUTPUT PANEL CONTROLS 3 or 4 FIGURE B.1 10.

  • Page 22: Engine Operation

    ENGINE OPERATION Starting/Shutdown Instructions Be sure all Pre-Operation Engine Service has been performed. Also, Read owners manual before starting for the first time. (See INSTALLATION section) Remove all loads connected to the AC power recepta- cles. Before starting, first open the fuel shutoff valve. Always pull the choke control out when starting the engine;...

  • Page 23: Welding Operation

    The OUTBACK® 185 generator power can be used to supply up to 5,200 watts continuous input power to a Lincoln Wire Feeder/Welder. The Wire Feeder/ Welder is equipped with all the supplies needed for Flux-Cored Arc Welding (FCAW). Also some Wire Feeder/Welders come...

  • Page 24: Auxiliary Power Operation

    120V Receptacle Operation: • Set the Output Control on the Pro-Cut 25 no higher than the 15 amp position.( Higher settings may cause circuit breaker on the OUTBACK® 185 to trip.) • Maximum material thickness that can be cut is 1/4". 240V Receptacle Operation: •...

  • Page 25: Auxiliary Power Application

    *Submersible Pump - 1 HP *Sump Pump Toaster Weed Trimmer Lincoln Wire Feeder/Welder NOTES: Wattages listed are approximate. Check your equipment for actual wattage. Equipment with unusually high *START-UP WATTS are listed. For start-up of other equipment that uses a motor, listed in the table, multiply RUNNING WATTS by 2.
  • Page 26 NOTES B-10 B-10 OUTBACK® 185...
  • Page 27 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Options / Accessories .
  • Page 28 OPTIONS/ACCESSORIES The following options/accessories are available for your OUTBACK®185 from your local Lincoln Distributor: Accessory Kit (K875) – Includes the following: • Twenty feet (6.1 meters) of #6 AWG electrode cable with lug. • Fifteen feet (4.6 meters) of #6 work cable with lugs. •...
  • Page 29 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Service Instructions .

  • Page 30: Maintenance

    MAINTENANCE OUTBACK® 185...

  • Page 31: Safety Precautions

    SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove guards only when necessary to perform maintenance and replace them when the mainte- nance requiring their removal is complete. •...

  • Page 32: Engine Adjustments

    Do not attempt to polish slip rings while engine is running. ----------------------------------------------------------------------- HARDWARE Both English and Metric fasteners are used in this welder. ENGINE MAINTENANCE PARTS Kohler CS 12.75 Air Filter Element Air Filter Pre-Cleaner Spark Plug...

  • Page 33: Major Component Locationss

    MAINTENANCE 1. CRADLE ASBLY, BATTERY & ROOF 2. CONTROL PANEL ASSEMBLY 3. STATOR & ROTOR ASSEMBLY 4. REAR CONTROL PANEL & FUEL TANK ASSEMBLY 5. ENGINE ASSEMBLY MAJOR COMPONENT LOCATION OUTBACK® 185...
  • Page 34 NOTES OUTBACK® 185...
  • Page 35 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 Engine Starting, Protection and Battery Charging .
  • Page 36 THEORY OF OPERATION FIGURE E.2 - ENGINE STARTING, PROTECTION AND BATTERY CHARGING OIL LEVEL INDICATOR LEVEL MODULE (KOHLER) OIL LEVEL SWITCH IGNITION ENGINE STARTER ALTERNATOR SOLENOID SOLENOID 10 AMP FUSE AUTO HIGH START BATTERY HOUR METER ENGINE STARTING, PROTECTION AND BATTERY CHARGING ENGINE STARTING A 12 Volt battery supplies power to the rotary run/stop/idle switch through a fuse that is located...

  • Page 37: Theory Of Operation

    THEORY OF OPERATION FIGURE E.3 - ENGINE STARTING, PROTECTION AND BATTERY CHARGING OIL LEVEL INDICATOR LEVEL MODULE (KOHLER) OIL LEVEL SWITCH IGNITION ENGINE STARTER ALTERNATOR SOLENOID SOLENOID 10 AMP FUSE AUTO HIGH START BATTERY HOUR METER ENGINE STARTING, PROTECTION AND BATTERY CHARGING (contin- ued) BATTERY CHARGING The Kohler engine has a built-in battery charging sys-...
  • Page 38 THEORY OF OPERATION FIGURE E.4 - AUTOMATIC IDLE SYSTEM OIL LEVEL INDICATOR LEVEL MODULE (KOHLER) OIL LEVEL SWITCH IGNITION ENGINE STARTER ALTERNATOR SOLENOID SOLENOID 10 AMP FUSE AUTO HIGH START BATTERY HOUR METER AUTOMATIC IDLE SYSTEM The Outback® 185 is equipped with an automatic engine idle system.
  • Page 39 THEORY OF OPERATION OIL LEVEL INDICATOR LEVEL MODULE (KOHLER) OIL LEVEL SWITCH IGNITION ENGINE STARTER ALTERNATOR SOLENOID SOLENOID 10 AMP FUSE AUTO HIGH START BATTERY HOUR METER GENERATING 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”...
  • Page 40 THEORY OF OPERATION OIL LEVEL INDICATOR LEVEL MODULE (KOHLER) OIL LEVEL SWITCH IGNITION ENGINE STARTER ALTERNATOR SOLENOID SOLENOID 10 AMP FUSE AUTO HIGH START BATTERY HOUR METER GENERATING 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.
  • Page 41 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 42: How To Use Troubleshooting Guide

    TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 43: Pc Board Troubleshooting Procedures

    - If the PC board uses protective shorting jumpers, don’t remove them until installation is complete. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- er failure analysis.
  • Page 44 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 45 The engine will not shut down. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 46 The engine runs erratically or stops running. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 47 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 48 Engine runs normally. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 49 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS 1.
  • Page 50 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 51 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 52 NOTES F-12 F-12 OUTBACK® 185...

  • Page 53: Engine Rpm Adjustment Procedure

    F-13 ENGINE RPM ADJUSTMENT PROCEDURE 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 throughout this manual.
  • Page 54 TROUBLESHOOTING AND REPAIR F-14 ENGINE RPM ADJUSTMENT PROCEDURE (continued) FIGURE F.1 – STROBE-TACH METHOD PROCEDURE Strobe-Tach Method 1. Turn 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.
  • Page 55 Throttle Adjustment Procedure later in this section. NOTE: For the Outback® 185, and any other Lincoln Electric 3600 RPM (2 Pole) machine, engine RPM can be determined by multiplying the frequency, in Hz. by 60. (Example: 60 Hz. x 60 = 3600 RPM).
  • Page 56 TROUBLESHOOTING AND REPAIR F-16 ENGINE RPM ADJUSTMENT PROCEDURE (continued) LOW IDLE ADJUSTMENT 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 manufacturer’s instructions for the Vibratach.

  • Page 57: Throttle Adjustment Procedure

    THROTTLE ADJUSTMENT PROCEDURE WARNING 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 throughout this manual.
  • Page 58 TROUBLESHOOTING AND REPAIR F-18 THROTTLE ADJUSTMENT PROCEDURE (continued) FIGURE F.4 – HIGH AND LOW IDLE ADJUSTMENT LOW IDLE ADJUSTMENT PROCEDURE High Idle Adjustment Check that the linkage attaching the solenoid to the engine speed control lever is in good condition and moves freely.

  • Page 59: Brush And Slip Ring Procedure

    F-19 BRUSH AND SLIP RING SERVICE PROCEDURE 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 throughout this manual.
  • Page 60 TROUBLESHOOTING AND REPAIR F-20 BRUSH AND SLIP RING SERVICE PROCEDURE (continued) FIGURE F.5 – BRUSH HOLDER ASSEMBLY LOCATION SCREWS (2) LOCKING TABS COVER 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 the cover.
  • Page 61 TROUBLESHOOTING AND REPAIR F-21 BRUSH AND SLIP RING SERVICE PROCEDURE (continued) FIGURE F.6 – BRUSH REMOVAL AND REPLACEMENT CABLE TIE BRUSHES 9. Check for evidence of sticking brushes. Sticking brushes will normally result in the slip rings being pitted and discolored from exces- sive arcing.
  • Page 62 NOTES F-22 F-22 OUTBACK® 185...
  • Page 63 F-23 ROTOR FLASHING AND VOLTAGE TEST 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 throughout this manual.

  • Page 64: Rotor Flashing And Voltage

    TROUBLESHOOTING AND REPAIR F-24 ROTOR FLASHING AND VOLTAGE TEST (continued) FIGURE F.7 – BRUSH AND SLIP RING LOCATIONS SLIP RINGS BRUSHES 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.
  • Page 65 F-25 BATTERY CHARGING SYSTEM TEST 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 throughout this manual.
  • Page 66 TROUBLESHOOTING AND REPAIR F-26 BATTERY CHARGING SYSTEM TEST (continued) BATTERY PROCEDURE WARNING REMOVE CABLE WHILE MACHINE IS RUN- NING, OR ATTEMPT TO OPERATE THE ENGINE WITHOUT A BAT- TERY CONNECTED. Serious dam- age to the PC board may result. 1. Be sure the battery is fully charged, in good condition and is securely connected.

  • Page 67: Stator Voltage Test

    TROUBLESHOOTING AND REPAIR F-27 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 throughout this manual.
  • Page 68 TROUBLESHOOTING AND REPAIR F-28 STATOR VOLTAGE TEST (continued) FIGURE F.9 – HIGH AND LOW IDLE ADJUSTMENT LOW IDLE ADJUSTMENT PROCEDURE 1. Verify 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.

  • Page 69: Rotor Resistance And Ground Test (Static

    F-29 ROTOR RESISTANCE AND GROUND TEST (STATIC) 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 throughout this manual.
  • Page 70 TROUBLESHOOTING AND REPAIR F-30 ROTOR RESISTANCE AND GROUND TEST (STATIC) (continued) SLIP RINGS BRUSHES 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.

  • Page 71: Rotor Resistance And Ground Test (Dynamic

    ROTOR RESISTANCE AND GROUND TEST (DYNAMIC) WARNING 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 throughout this manual.
  • Page 72 TROUBLESHOOTING AND REPAIR F-32 ROTOR RESISTANCE AND GROUND TEST (DYNAMIC) (continued) FIGURE F.11 – BRUSH AND SLIP RING LOCATIONS SLIP RINGS BRUSHES PROCEDURE NOTE: This test is performed using a good quali- ty analog type ohmmeter. meters will not provide stable or accurate resistance readings while the rotor is spin- ning.

  • Page 73: Stator Short Circuit And Ground

    F-33 STATOR SHORT CIRCUIT AND GROUND TEST 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 throughout this manual.
  • Page 74 TROUBLESHOOTING AND REPAIR F-34 STATOR 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.

  • Page 75: Weld Boost System Test

    F-35 WELD BOOST SYSTEM TEST 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 throughout this manual.
  • Page 76 TROUBLESHOOTING AND REPAIR F-36 WELD BOOST SYSTEM TEST (continued) FIGURE F.12 – HIGH AND LOW IDLE ADJUSTMENT LOW IDLE ADJUSTMENT PROCEDURE 1. Check that the CB4 circuit breaker is not tripped. 2. Check that the battery is fully charged and in good condition.

  • Page 77: Case Cover Removal And Replacement Procedure

    CASE COVER REMOVAL AND REPLACEMENT PROCEDURE WARNING 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 throughout this manual.
  • Page 78 TROUBLESHOOTING AND REPAIR F-38 CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.13 – CASE COVER REMOVAL CASE SCREWS PROCEDURE 1. Using a 3/8” wrench, remove all screws from the top of the red sheet metal cover. 2. Lift the top cover off of the machine 3.

  • Page 79: Fuel Tank And Enclosure Removal And Replacement Procedure

    FUEL TANK AND ENCLOSURE REMOVAL AND REPLACEMENT PROCEDURE 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 throughout this manual.
  • Page 80 TROUBLESHOOTING AND REPAIR F-40 FUEL TANK AND ENCLOSURE REMOVAL AND REPLACEMENT PROCEDURE (continued) FUEL TANK 3/8’ SCREWS PROCEDURE WARNING Because gasoline is highly flammable, the following procedures should be done in a well-ventilated area; far away from flame, sparks, or any other sources of ignition.
  • Page 81 TROUBLESHOOTING AND REPAIR F-41 F-41 FUEL TANK AND ENCLOSURE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.15 – BATTERY LOCATION MOUNTING BRACKET BATTERY OUTBACK® 185...
  • Page 82 NOTES F-42 F-42 OUTBACK® 185...

  • Page 83: Control Box Removal And Replacement Procedure

    F-43 CONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE 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 throughout this manual.
  • Page 84 TROUBLESHOOTING AND REPAIR F-44 CONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.16 – CONTROL BOX REMOVAL FUEL TANK CONTROL BOX END PANEL PROCEDURE 1. Perform the Case Cover Removal Procedure. 2. Using the 7/16” wrench, loosen battery mount- ing bracket. See Figure F.16. 3.
  • Page 85 TROUBLESHOOTING AND REPAIR F-45 F-45 CONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.17 – BATTERY LOCATION MOUNTING BRACKET BATTERY OUTBACK® 185...
  • Page 86 NOTES F-46 F-46 OUTBACK® 185...

  • Page 87: Stator Removal And Replacement Procedure

    F-47 STATOR REMOVAL AND REPLACEMENT PROCEDURE 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 throughout this manual.
  • Page 88 TROUBLESHOOTING AND REPAIR F-48 STATOR REMOVAL AND REPLACEMENT PROCEDURE (continued) TOLERANCE RING BRUSH ASSEMBLY BEARING BRACKET END COVER 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 connecting the engine/generator assembly to the tubular frame.
  • Page 89 TROUBLESHOOTING AND REPAIR F-49 STATOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.19 – NUTS & RUBBER ENGINE MOUNTS 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. Important! Always use a new tolerance ring when reassembling the brush-end end bracket.
  • Page 90 TROUBLESHOOTING AND REPAIR F-50 STATOR REMOVAL AND REPLACEMENT PROCEDURE (continued) TOLERANCE RING 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 not penetrate the air gap any far- ther than any tapered portion on the end of the...

  • Page 91: Rotor Removal And Replacement Procedure

    F-51 ROTOR REMOVAL AND REPLACEMENT PROCEDURE 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 throughout this manual.
  • Page 92 TROUBLESHOOTING AND REPAIR F-52 ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. Perform the Stator Removal Procedure. 2. Remove the long through-bolt from the bearing end of the rotor. (An impact wrench works best for removing this through-bolt). F.21. 3. Remove the rotor from the engine crankshaft using the Lincoln rotor-pulling tool.

  • Page 93: Retest After Repair

    TROUBLESHOOTING AND REPAIR F-53 F-53 RETEST AFTER REPAIR PROCEDURE No-load test values High idle (No load) RPM: 3700-3800 RPM (61.7 – 63.3 Hz) Low idle RPM: 2250-2500 RPM (37.5 – 41.7 Hz) Weld terminal open Circuit Voltage (OCV): Weld control at maximum: 70 – 80 VDC Weld control at minimum: 45 –...
  • Page 94 NOTES F-54 F-54 OUTBACK® 185...
  • Page 95 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram - Complete Machine Code 11516 (L13878) .

  • Page 96: Electrical Diagrams

    WiriNG DiaGram - cOmplETE machiNE cODE 11516 (l13878) LEVEL MODULE BLUE BLACK BLACK LEVEL SENSOR SPARK (CLOSED W HEN PLUG OIL LEVEL IS TOO LOW) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. ElEcTrical DiaGramS WIRING DIAGRAM - OUTBACK 185 GND-J...

  • Page 97: Schematic - Complete Machine Code 11516 (G6205

    SchEmaTic - cOmplETE machiNE cODE 11516 (G6205) G6205 ENGINEERING CONTROLLED RELEASED A.02 FROM X. CHANGE DETAIL: MANUFACTURER: GND-J insulated inline LEVEL connectors MODULE topleft engine top engine area Kohlers' part BLUE BLACK magneto type SOLENOID 15 ohms 12 volt dc top left rear engine BLACK Energized for LOW idle...

  • Page 98: Schematic - Field Control / Idle Pc Board (G4793-1

    SchEmaTic - FiElD cONTrOl / iDlE pc BOarD (G4793-1) + DIODES 5.1K 0.05uF 130V 600V - DIODES SNUBBER 12VDC CASE 200V 200V 330uF 330uF 100V 100V CASE 0.1uF TOROID 0.1uF 47.5 0.1uF 100K 100K 0.1uF 47.5 224N TP-B 600V CASE +10V 0.022uF 0.022uF...

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