Lincoln Electric SVM204-A service manual Cable Size and Length, Cable Amps Length 30% Duty Cycle

Page 13

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A-5

INSTALLATION

 

A-5

 

 

OUTBACK® 185 OUTPUT CONNECTIONS

 

8

1

4

5

7

 

9

 

 

6

 

 

 

10

 

 

 

3

2

FIGURE A.1

1.

CURRENT CONTROL DIAL

7.

DUPLEX RECEPTACLE (2)- 120 VOLT, 20 AMP

2.

WELD OUTPUT TERMINALS (2)

8.

HOURMETER

3.

GROUND STUD

9.

ENGINE SWITCH

4.

CIRCUIT BREAKERS (2) - 20 AMP

10. CHOKE

5.CIRCUIT BREAKER 30 Amp

6.RECEPTACLE - 240 VOLT, 50 AMP

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ELECTRICAL OUTPUT CONNECTIONS

See Figure A.1 for the location of the current control dial, weld output terminals, ground stud, circuit break- ers, 240 and 120 volt receptacles.

WELDING CABLE CONNECTIONS

Cable Size and Length

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. Cable diameters are increased for long cable lengths to reduce voltage drops.

TABLE A.1

RECOMMENDED WELDING CABLE

SIZE AND LENGTH

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

 

Cable

125 Amps

 

 

Length

30% Duty Cycle

 

0-50 ft

(0-15m)

6 AWG

 

 

 

 

 

 

50-100 ft

(15-30 m)

5 AWG

 

 

 

 

 

 

100-150 ft

(30-46 m)

3 AWG

 

 

 

 

 

 

150-200 ft

(46-61 m)

2 AWG

 

 

 

 

 

 

200-250 ft

(61-76m)

1 AWG

 

 

 

 

 

 

 

 

 

 

OUTBACK® 185

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Contents Outback California Proposition 65 Warnings SafetyCan be dangerous Electric Shock can kill ARC Rays can burnWelding Cutting Powered equipmentCylinder may explode Sparks can cause fire or If damaged ExplosionSûreté Pour Soudage a L’Arc Précautions DE SûretéSafety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Outback 185 K2706-1 InstallationAC Auxiliary Power Bore x StrokeLocation and Ventilation Safety PrecautionsStoring Stacking PRE-OPERATION Engine ServiceTilting OILCable Amps Length 30% Duty Cycle Cable Size and LengthMachine Grounding Cable InstallationPremises Wiring Auxiliary Power ReceptaclesCircuit Breakers See Figure A.1Type Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the OutbackTable of Contents Operation Section Operation Safety InstructionsOIL AIR Cleaner Fuel Graphic Symbols Used on this Equipment or in this ManualWork Clamp Ground Auxiliary Power BreakerOperational Features and Controls Design Features AdvantagesGeneral Description Recommended ApplicationsWELDER/GENERATOR Controls When in Auto IdleStopping the Engine Engine OperationWith a Lincoln Wire Only qualified Personnel should install, use, orService this equipment Electric Shock can kill240V Receptacle Operation 120V Receptacle OperationTable B.3 Auxiliary Power Applications Outback Table of Contents Accessories Section OPTIONS/ACCESSORIES AccessoriesTable of Contents Maintenance Section Maintenance Tighten dipstick firmly before starting Safety PrecautionsKohler CS To service the pre-cleanerMaintenance Outback 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Engine STARTING, Protection and Battery ChargingEngine STARTING, Protection and Battery Charging contin- ued Figure E.4 Automatic Idle System Automatic Idle SystemFlashing Generating PowerBuilding Output AC Output DC Weld Output Generating PowerWeld Output Control Weld Boost1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide Troubleshooting and RepairLocate PROBLEM SYMPTOM PC Board Troubleshooting Procedures This plug disables the normal DisconnectingEngine switch Engine shut down functionTroubleshooting and Repair Problems Symptoms Procedure Engine RPM adjustmentAdjustment procedure Troubleshooting and Repair Tests Perform the stator resistance Voltage tests Voltage, and resistanceEngine Brush and slip ring serviceBrush and slip Ring Service procedureCircuit tests Outback Test Description Engine RPM Adjustment ProcedureStrobe-Tach Method Engine RPM Adjustment ProcedureFrequency Counter Method Control LeverVibratach Method TOP View of EngineThrottle Adjustment Procedure High Idle Adjustment Throttle Adjustment ProcedureLow Idle Adjustment Procedure Description Brush and Slip Ring Service ProcedureFigure F.5 Brush Holder Assembly Location Brush and Slip Ring Service ProcedureCable TIE Brushes Cleaning Slip RingsOutback Rotor Flashing and Voltage Test Set the output control to maximum Battery Charging System Test Figure F.8 Charging System Stator Voltage Test Stator Voltage Test Figure F.9 High and LOW Idle AdjustmentRotor Resistance and Ground Test Static Rotor Resistance and Ground Test Static Slip Rings BrushesRotor Resistance and Ground Test Dynamic Figure F.11 Brush and Slip Ring Locations Rotor Resistance and Ground Test DynamicStator Short Circuit and Ground Test Stator Short Circuit and Ground Test Perform Case Cover Removal ProcedureWeld Boost System Test Weld Boost System Test Figure F.12 High and LOW Idle AdjustmentCase Cover Removal and Replacement Procedure Figure F.13 Case Cover Removal Case Cover Removal and Replacement ProcedureFuel Tank and Enclosure Removal and Replacement Procedure Perform the Case Cover Removal Procedure Removal and Replacement ProcedureFuel Tank and Enclosure Mounting Bracket Battery Outback Control BOX Removal and Replacement Procedure Perform the Fuel Tank and Enclosure Removl Procedure Control BOX Removal and Replacement ProcedureMounting Bracket Battery Outback Stator Removal and Replacement Procedure Perform the Control Box Removal Procedure Stator Removal and Replacement ProcedureFigure F.19 Nuts & Rubber Engine Mounts Installing the stator assemblyTolerance Ring Stator Rotor Removal and Replacement Procedure Perform the Stator Removal Procedure Rotor Removal and Replacement ProcedureReplacing the Rotor No-load test values Retest After RepairFull load test values Volt receptaclesOutback Table of Contents Diagram Section OUTBacK Wiring Diagram OutbackSchEmaTic cOmplETE machiNE cODE 11516 G6205 Equipmenttype