Lincoln Electric SVM204-A Electric Shock can kill ARC Rays can burn, Can be dangerous

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ii

 

 

 

 

 

 

SAFETY

 

 

 

 

 

 

 

ii

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRIC SHOCK can kill.

 

 

 

 

 

 

ARC RAYS can burn.

 

3.a. The electrode and work (or ground) circuits

 

 

 

 

 

 

4.a. Use a shield with the proper filter and cover

 

are electrically “hot” when the welder is on.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

plates to protect your eyes from sparks and

 

 

 

 

 

 

 

 

 

Do not touch these “hot” parts with your bare

 

 

 

 

 

 

 

the rays of the arc when welding or observing

 

skin or wet clothing. Wear dry, hole-free

 

 

 

 

 

 

 

open arc welding. Headshield and filter lens

 

gloves to insulate hands.

 

 

 

 

 

 

 

 

 

should conform to ANSI Z87. I standards.

3.b. Insulate yourself from work and ground using dry insulation.

 

4.b. Use suitable clothing made from durable flame-resistant

Make certain the insulation is large enough to cover your full

 

 

 

 

 

material to protect your skin and that of your helpers from

area of physical contact with work and ground.

 

 

 

 

 

the arc rays.

 

 

 

 

 

 

In addition to the normal safety precautions, if welding

 

4.c. Protect other nearby personnel with suitable, non-flammable

must be performed under electrically hazardous

 

 

 

 

 

screening and/or warn them not to watch the arc nor expose

conditions (in damp locations or while wearing wet

 

 

 

 

 

themselves to the arc rays or to hot spatter or metal.

clothing; on metal structures such as floors, gratings or

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

scaffolds; when in cramped positions such as sitting,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FUMES AND GASES

 

kneeling or lying, if there is a high risk of unavoidable or

 

 

 

 

 

 

 

 

accidental contact with the workpiece or ground) use

 

 

 

 

 

 

 

can be dangerous.

 

the following equipment:

 

 

 

 

 

 

 

 

 

 

 

 

• Semiautomatic DC Constant Voltage (Wire) Welder.

 

 

 

 

 

 

 

5.a. Welding may

produce

fumes and gases

• DC Manual (Stick) Welder.

 

 

 

 

 

 

 

 

 

 

hazardous to health. Avoid breathing these

 

 

 

 

 

 

 

 

 

 

• AC Welder with Reduced Voltage Control.

 

 

 

 

 

 

 

fumes and gases.When welding, keep

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

your head out of the fume. Use enough

3.c. In semiautomatic or automatic wire welding, the electrode,

 

 

 

 

 

 

 

ventilation and/or exhaust at the arc to keep

 

 

 

 

 

fumes

and

gases

away from

the breathing

zone. When

electrode

reel,

welding head, nozzle

or

semiautomatic

 

 

 

 

 

 

 

 

 

 

welding

with

electrodes

which

require

special

welding gun are also electrically “hot”.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ventilation such as stainless or hard facing (see

 

 

 

 

 

 

 

 

 

 

 

 

 

3.d. Always be

sure

the

work

cable

makes

a

good electrical

 

 

 

 

 

instructions on

container

or MSDS) or

on

lead or

 

 

 

 

 

cadmium

plated

steel and

other metals

or

coatings

connection

with

the

metal

being

welded. The connection

 

 

 

 

 

 

 

 

 

 

which produce highly toxic fumes, keep exposure as

should be as close as possible to the area being welded.

 

 

 

 

 

 

 

 

 

 

low as possible and within applicable OSHA PEL and

 

 

 

 

 

 

 

 

 

 

 

 

 

3.e. Ground the work or metal to be welded to a good electrical

 

 

 

 

 

ACGIH TLV limits using local exhaust or mechanical ven-

 

 

 

 

 

tilation. In confined spaces or in some circumstances,

(earth) ground.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

outdoors, a respirator may be required. Additional pre-

 

 

 

 

 

 

 

 

 

 

 

 

 

3.f. Maintain the electrode holder, work clamp, welding cable and

 

 

 

 

 

cautions are also required when welding on galvanized

 

 

 

 

 

steel.

 

 

 

 

 

 

 

 

welding machine in good, safe operating condition. Replace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

damaged insulation.

 

 

 

 

 

 

5. b. The operation of welding fume control equipment is affected

 

 

 

 

 

 

 

 

 

3.g. Never dip the electrode in water for cooling.

 

 

 

 

 

 

by various factors including proper use and positioning of the

 

 

 

 

 

 

equipment, maintenance of the equipment and the specific

 

 

 

 

 

 

 

 

 

 

 

 

 

3.h. Never simultaneously touch electrically

“hot” parts of

 

 

 

 

 

welding procedure and application involved. Worker expo-

 

 

 

 

 

sure level should be checked upon installation and periodi-

electrode holders connected to two welders because voltage

 

 

 

 

 

 

 

 

 

 

cally thereafter to be certain it is within applicable OSHA PEL

between the two can be the total of the open circuit voltage

 

 

 

 

 

 

 

 

 

 

and ACGIH TLV limits.

 

 

 

 

 

of both welders.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3.i. When working above floor level, use a safety belt to protect

 

5.c. Do not weld in locations near chlorinated hydrocarbon vapors

 

 

 

 

 

coming from degreasing, cleaning or spraying operations.

yourself from a fall should you get a shock.

 

 

 

 

 

 

 

 

 

 

 

 

The heat and rays of the arc can react with solvent vapors to

 

 

 

 

 

 

 

 

 

 

 

 

 

3.j. Also see Items 6.c. and 8.

 

 

 

 

 

 

 

 

 

form phosgene, a highly toxic gas, and other irritating prod-

 

 

 

 

 

 

 

 

 

ucts.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5.d. Shielding gases used for arc welding can displace air and

 

 

 

 

 

 

 

 

 

 

 

 

 

cause injury or death. Always use enough ventilation,

 

 

 

 

 

 

 

 

 

 

 

 

 

especially in confined areas, to insure breathing air is safe.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5.e. Read and understand the manufacturer’s instructions for this

 

 

 

 

 

 

 

 

 

 

 

 

 

equipment and the consumables to be used, including the

 

 

 

 

 

 

 

 

 

 

 

 

 

material safety data sheet (MSDS) and follow your

 

 

 

 

 

 

 

 

 

 

 

 

 

employer’s safety practices. MSDS forms are available from

 

 

 

 

 

 

 

 

 

 

 

 

 

your

welding distributor

or

from

the

manufacturer.

 

 

 

 

 

 

 

 

 

5.f. Also see item 1.b.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTBACK® 185

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Contents Outback California Proposition 65 Warnings SafetyCan be dangerous Electric Shock can kill ARC Rays can burnSparks can cause fire or If damaged Explosion Powered equipmentWelding Cutting Cylinder may explodeSûreté 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 Bore x Stroke InstallationTechnical Specifications Outback 185 K2706-1 AC Auxiliary PowerSafety Precautions Location and VentilationStoring OIL PRE-OPERATION Engine ServiceStacking TiltingCable Amps Length 30% Duty Cycle Cable Size and LengthMachine Grounding Cable InstallationSee Figure A.1 Auxiliary Power ReceptaclesPremises Wiring Circuit BreakersType Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the OutbackTable of Contents Operation Section Operation Safety InstructionsBreaker Graphic Symbols Used on this Equipment or in this ManualOIL AIR Cleaner Fuel Work Clamp Ground Auxiliary PowerRecommended Applications Design Features AdvantagesOperational Features and Controls General DescriptionWELDER/GENERATOR Controls When in Auto IdleStopping the Engine Engine OperationElectric Shock can kill Only qualified Personnel should install, use, orWith a Lincoln Wire Service this equipment240V 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 SystemGenerating Power FlashingBuilding Output AC Output Weld Boost Generating PowerDC Weld Output Weld Output Control1TABLE of Contents Troubleshooting and Repair F-1 Troubleshooting and Repair HOW to USE Troubleshooting GuideLocate PROBLEM SYMPTOM PC Board Troubleshooting Procedures Engine shut down function DisconnectingThis plug disables the normal Engine switchTroubleshooting and Repair Problems Symptoms Engine RPM adjustment ProcedureAdjustment procedure Troubleshooting and Repair Tests Perform the stator resistance Voltage tests Voltage, and resistanceEngine Brush and slip ring serviceService procedure Brush and slip RingCircuit 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 Throttle Adjustment Procedure High Idle AdjustmentLow 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 Removal and Replacement Procedure Perform the Case Cover Removal 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 Rotor Removal and Replacement Procedure Perform the Stator Removal ProcedureReplacing the Rotor Volt receptacles Retest After RepairNo-load test values Full load test valuesOutback Table of Contents Diagram Section OUTBacK Wiring Diagram OutbackSchEmaTic cOmplETE machiNE cODE 11516 G6205 Equipmenttype