Lincoln Electric SVM204-A service manual Machine Grounding, Cable Installation

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A-6

INSTALLATION

A-6

 

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Cable Installation

Install the welding cables to your OUTBACK® 185 as follows. See Figure A.1 for the location of parts.

1.The gasoline engine must be OFF to install weld- ing cables.

2.Remove the 1/2-13 flanged nuts from the output terminals.

3.Connect the electrode holder and work cables to the weld output terminals. Normally, the electrode cable is connected to the positive (+) output stud.

4.Tighten the flanged nuts securely.

5.Be certain that the metal piece you are welding (the “work”) is securely connected to the work clamp and cable.

6.Check and tighten the connections periodically.

CAUTION

Loose connections will cause the output studs to overheat and the studs may eventually melt.

Do not cross welding cables at output stud connec- tion. Keep isolated and separate from one another.

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Lincoln Electric offers a welding accessory kit with #6 welding cables. See the ACCESSORIES section of this manual for more information.

For more information on welding , see WELDING OPERATION in the OPERATION section of this man- ual.

MACHINE GROUNDING

Because this portable engine driven welder or genera- tor creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (your home, shop, etc.).

To prevent dangerous electric shock, other equipment to which this engine driven welder supplies power, must:

a)be grounded to the frame of the welder using a grounded type plug

or

b)be double insulated

When this welder is mounted on a truck or trailer, the

machine grounding stud must be securely con- nected to the metal frame of the vehicle.

In general if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints, or to the metal framework of a building which has been effectively grounded. The U.S. National Electrical Code lists a number of alternate means of grounding electrical equipment. A machine grounding

stud marked with the symbol is provided on the front of the welder.

WARNING

DO NOT GROUND MACHINE TO A PIPE WHICH CAR- RIES EXPLOSIVE OR COMBUSTIBLE MATERIAL.

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OUTBACK® 185

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Contents Outback Safety California Proposition 65 WarningsElectric Shock can kill ARC Rays can burn Can be dangerousCylinder may explode Powered equipmentWelding Cutting Sparks can cause fire or If damaged ExplosionPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcSafety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section AC Auxiliary Power InstallationTechnical Specifications Outback 185 K2706-1 Bore x StrokeStoring Safety PrecautionsLocation and Ventilation Tilting PRE-OPERATION Engine ServiceStacking OILCable Size and Length Cable Amps Length 30% Duty CycleCable Installation Machine GroundingCircuit Breakers Auxiliary Power ReceptaclesPremises Wiring See Figure A.1Table A.2 Electrical Device USE with the Outback Type Common Electrical Devices Possible ConcernsTable of Contents Operation Section Safety Instructions OperationWork Clamp Ground Auxiliary Power Graphic Symbols Used on this Equipment or in this ManualOIL AIR Cleaner Fuel BreakerGeneral Description Design Features AdvantagesOperational Features and Controls Recommended ApplicationsWhen in Auto Idle WELDER/GENERATOR ControlsEngine Operation Stopping the EngineService this equipment Only qualified Personnel should install, use, orWith a Lincoln Wire Electric Shock can kill120V Receptacle Operation 240V Receptacle OperationTable B.3 Auxiliary Power Applications Outback Table of Contents Accessories Section Accessories OPTIONS/ACCESSORIESTable of Contents Maintenance Section Maintenance Safety Precautions Tighten dipstick firmly before startingTo service the pre-cleaner Kohler CSMaintenance Outback 1TABLE of CONTENTS-THEORY of Operation Section E-1 Engine STARTING, Protection and Battery Charging Theory of OperationEngine STARTING, Protection and Battery Charging contin- ued Automatic Idle System Figure E.4 Automatic Idle SystemBuilding Output AC Output Generating PowerFlashing Weld Output Control Generating PowerDC Weld Output Weld Boost1TABLE of Contents Troubleshooting and Repair F-1 Locate PROBLEM SYMPTOM Troubleshooting and RepairHOW to USE Troubleshooting Guide PC Board Troubleshooting Procedures Engine switch DisconnectingThis plug disables the normal Engine shut down functionTroubleshooting and Repair Problems Symptoms Adjustment procedure Engine RPM adjustmentProcedure Troubleshooting and Repair Voltage, and resistance Tests Perform the stator resistance Voltage testsBrush and slip ring service EngineCircuit tests Service procedureBrush and slip Ring Outback Engine RPM Adjustment Procedure Test DescriptionEngine RPM Adjustment Procedure Strobe-Tach MethodControl Lever Frequency Counter MethodTOP View of Engine Vibratach MethodThrottle Adjustment Procedure Low Idle Adjustment Throttle Adjustment ProcedureHigh Idle Adjustment Brush and Slip Ring Service Procedure Procedure DescriptionBrush and Slip Ring Service Procedure Figure F.5 Brush Holder Assembly LocationCleaning Slip Rings Cable TIE BrushesOutback Rotor Flashing and Voltage Test Set the output control to maximum Battery Charging System Test Figure F.8 Charging System Stator Voltage Test Figure F.9 High and LOW Idle Adjustment Stator Voltage TestRotor Resistance and Ground Test Static Slip Rings Brushes Rotor Resistance and Ground Test StaticRotor Resistance and Ground Test Dynamic Rotor Resistance and Ground Test Dynamic Figure F.11 Brush and Slip Ring LocationsStator Short Circuit and Ground Test Perform Case Cover Removal Procedure Stator Short Circuit and Ground TestWeld Boost System Test Figure F.12 High and LOW Idle Adjustment Weld Boost System TestCase Cover Removal and Replacement Procedure Case Cover Removal and Replacement Procedure Figure F.13 Case Cover RemovalFuel Tank and Enclosure Removal and Replacement Procedure Fuel Tank and Enclosure Removal and Replacement ProcedurePerform the Case Cover Removal Procedure Mounting Bracket Battery Outback Control BOX Removal and Replacement Procedure Control BOX Removal and Replacement Procedure Perform the Fuel Tank and Enclosure Removl ProcedureMounting Bracket Battery Outback Stator Removal and Replacement Procedure Stator Removal and Replacement Procedure Perform the Control Box Removal ProcedureInstalling the stator assembly Figure F.19 Nuts & Rubber Engine MountsTolerance Ring Stator Rotor Removal and Replacement Procedure Replacing the Rotor Rotor Removal and Replacement ProcedurePerform the Stator Removal Procedure Full load test values Retest After RepairNo-load test values Volt receptaclesOutback Table of Contents Diagram Section Wiring Diagram Outback OUTBacKSchEmaTic cOmplETE machiNE cODE 11516 G6205 Equipmenttype