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Lincoln Electric OUTBACK SVM204-A User's Manual

1. GENERAL INFORMATION ELECTRICAL SYMBOLS PER E153 CAPACITORS MFD 022 50V UNLESS OTHERWISE SPECIFIED RESISTORS Ohms 1 UNLESS OTHERWISE SPECIFIED LABELS DIODES 1 UNLESS OTHERWISE SPECIFIED A Sur ACE NE POWER SUPPLY SOURCE POIN V COMMON CONNECTION FRAME CONNECTION EARTH GROUND CONNECTION amp CONFIDENTIAL 15 PARTE i e i ToN DF ERR EQUIPMENT TYPE OUTBACK 185 E VELOPME 2 THE IN CHANGE AWN BY 9162 Y OF A COMPLETE BOARD THIS FRE 270 SUBJECT SCHEMATIC FIELD IDLE CONTROL 207 PAVING A CON mum Tuve APPROVED ms APPROVAL 21 2009 09021 5026038 6 4793 1G0 Return to Section TOC Return to Master TOC NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN 8 OUTBACK 185
2. c a 5 5 amp c Return to Section TOC Return to Master TOC OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i Q a cre 5 5 gt amp c Return to Section TOC Return to Master TOC Return to Master TOC 3 TROUBLESHOOTING AND REPAIR CONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 16 CONTROL BOX REMOVAL FUEL TANK CONTROL BOX END PANEL Disconnect the spark plug wire to prevent acci dental starting of the engine Replace three of the screws that had been removed when the fuel tank enclosure bottom was removed These screws are used to tem porarily secure the end panel on the control box Using Phillips screwdriver remove choke cable mounting Using pliers remove choke cable from engine 3 8 SCREWS PROCEDURE Perform the Case Cover Removal Procedure 9 Using the wiring diagram identify all of the wires wire splices and plugs that connect con Using the 7 16 wrench loosen battery mount trol box components to the engine and genera ing bracket See Figure F 16 tor If any wire or connector is not clearly 3 Remove the battery marked mark them so they can be properly reconnected It is also helpful to make notes as 4 Perform the Fuel Tank and Enclosure needed
3. F 43 c 2 E Stator Removal and Replacement Procedure 1 F 47 Rotor Removal and Replacement Procedure F 51 Retest and Repa is seu Ee er eR ERE Natur EXER Coed sde EORUM F 53 o 5 o gt 2 c OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e c Return to Section Return to Master TOC o 5 o E 2 E r TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhib it Find the listing that best describes the symptom that the machine is exhibiti
4. pee paie quus rer Fab D 2 Safety Precautions seii eie ua bre Dares da PE deb dae pus D 3 Routine and Periodic Maintenance 71 222 D 3 Engine Adjustments 1 D 4 SPRINGS eid bs A Vaux D 4 Engine Maintenance 1 D 4 Operational Clearance D 4 Major Component Locationss D 5 OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO gt Q amp a 21e 5 5 gt amp Return to Section TOC Return to Master TOC D 2 MAINTENANCE D 2 Service Instructions Single and Two Stage Engine Air Cleaners 1 Remove the Filter Unfasten or unlatch the service cover Because the filter fits tightly over the outlet tube to create the critical seal there will be some initial resistance similar to breaking Rotate the the seal on a jar Gently move the end of the filter ed while back and forth to break the seal then rotate while PNE pulling straight out Avoid knocking the filter straight o
5. 9 OIL LEVEL AUXIIARY WINDINGS e SWITCH ala SLIP STATOR RINGS c yo vsus OUTPUT OUTPUT IGNITION ENGINE ROTOR 3 WINDINGS STUDS 7 BRUSHES STARTER IUE EXCITER SOLENOID ALTERNATOR SOLENOID WINDING 9 ele ENGINE c ts SHUTDOWN o12 OUTPUT AUTOMATIC OUTPUT CONTROL IDLER CONTROL CIRCUIT D gt CIRCUIT K m m ala HOUR METER FIELD CONTROL PC BOARD ENGINE STARTING PROTECTION NOTE The engine charging system must be function AND BATTERY CHARGING contin al for the Outback amp 185 to produce weld or auxiliary output ued NOTE The battery must remain connected at all times If the battery is disconnected while the machine is run ning unstable voltage from the charging system will likely cause the PC board electronics to malfunction and may cause permanent damage to the PC board BATTERY 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 flashing system and the hour meter The remaining output exits the PC board is routed through a fuse located inside the control box and applied to the bat tery eio OJO f i Q amp a gt
6. GROUND STUD ON CONTROL PANEL FRONT LOW OIL INDICATOR LED GND K P4 5 5A tn i 2 GND I 5B 210B lt lt 210 NEUTRAL STUD 68 208 4 lt 208A ON CONTROL 213B lt 5 lt PANEL BOTTOM ar 215 66 215 AX 6 OPPOSITE 5B 15 SOLENOID BLACK 230 1 IGNITION P W d 209A 777 OIL 001 E LEVEL gs SENSOR lo SPARK CLOSED WHEN PLUG OILLEVEL 77 Return to Section TOC Return to Master TOC 12 IS TOO LOW wt POS BATTERY s L GND H GND GENERATOR SUPPORT FRAME GROUND eio gt c a 5 5 amp c 212 209 L13878PRINT Return to Section TOC Return to Master TOC 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 LINCOLN B OUTBACK 185 G 3 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i Q amp a 5 5 amp Return to Section TOC Return
7. Return to Master TOC Return to Master TOC o 5 o gt 2 E tc Return to Master TOC vi SAFETY vi 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 may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommenda tions If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equip ment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equip ment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions In parti
8. CAUTION 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 OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC c Return to Section TOC Return to Master TOC 5 o E 2 E tc ini TROUBLESHOOTING AND REPAIR a Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S OUTPUT PROBLEMS The engine will not go to high idle 1 Poor connection in weld circuit when a welding or auxiliary load is applied Engine idles up normally and outputs are normal when the engine switch is placed in the high position No weld or auxiliary output Engine runs normally check cables connectors work clamp and electrode holder Check that work clamp is making a good connection to the work piece Load too low to activate the idle circuit Plug in a device that applies a load of 100 watts or more NOTE Some tools and devices check for good power before fully turning on These devices will require the machine to be placed in the high position before they will function Make sure there is no load on the machine
9. HOUR METER FIELD CONTROL PC BOARD 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 diode Building Output The flashing current produces a weak magnetic field in the rotor which is coupled to the now running engine This rotating magnetic field begins to generate AC out put from all of the stator windings Output from the exciter winding is rectified by a diode bridge filtered by a capacitor controlled by circuitry on the PC board and fed back into the rotating field winding making the magnetic field stronger This stronger magnetic field then produces higher voltage from the stator windings which feeds back to the rotor making its magnetic field even stronger This process of strengthening the magnetic field through feedback from the exciter winding continues to increase the output of the main generator If the output control is set to maximum and the idle switch is in the high position all of the windings should be putting out maximum voltage almost immediately The rotor field voltage is now considerably higher than the flashing voltage that was used to start the generating process The flashing diode on the control PC board blocks that higher field voltage from intruding into the 12VDC battery system AC Output Th
10. Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispositifs de s ret leur place OUTBACK 185 LINCOLN B Return to Master TOC Return to Master TOC o 5 o gt 2 E tc Return to Master TOC SAFETY Electromagnetic Compatibility EMC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compat
11. 5 5 amp NOTE Unshaded areas of Block Logic Diagram are the subject of discussion OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i a 5 5 amp c Return to Section TOC Return to Master TOC THEORY OF OPERATION EM FIGURE E 4 AUTOMATIC IDLE SYSTEM CURRENT 120 VAC RECEPTACLES SENSOR 240 VAC RECEPTACLE OIL LEVEL gt Eg E OIL INDICATOR d 52 ES LEVEL MODULE 52 685 KOHLER REACTOR OIL LEVEL AUXIIARY WINDINGS 55 SWITCH SLIP STATOR RINGS EID OUTPUT 5 OUTPUT IGNITION ENGINE ROTOR WINDINGS M RECTIFIER STUDS 2 PHASE BRUSHES STARTER IDLE EXCITER POS 1 SOLENOID acrenveron SOLENOID WINDING BOOST 2 WINDING ENGINE gt SHUTDOWN RELAY OUTPUT AUTOMATIC OUTPUT CONTROL IDLER CONTROL CIRCUIT CIRCUIT 4 HOUR METER FIELD CONTROL PC BOARD AUTOMATIC ID
12. E FUEL TANK ENCLOSURE PROCEDURE 8 8 WARNING olo BED 5 Using pliers remove fuel line clamp located on s Because gasoline is highly gasoline valve 15 flammable the following 5 E procedures should be done in 6 Carefully remove the fuel line from the gasoline 4 a well ventilated area far valve away from flame sparks or 7 Flex the end of the sheet steel fuel tank enclo any other sources of ignition 1 Perform the Case Cover Removal Procedure 2 Close gasoline valve Red Lever located on bottom of gas tank sure out slightly and lift the tank out of the machine 8 If access to the top of the engine is required using the 3 8 wrench remove the five screws holding the bottom of the fuel tank enclosure 3 Using a 7 16 wrench disconnect the negative and lift it out of the machine ojo o battery cable See Figure F 15 Note washer 5 placement label and disconnect for reassem 8 bly o 5 4 Pump gasoline into an approved gasoline con 2 tainer c 5 3 o amp c OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i Q a 21e 5 5 gt amp Return to Section TOC Return to Master TOC rM TROUBLESHOOTING AND REPAIR FUEL TANK AND ENCLOSURE REMOVAL AND REPLACEMENT PROCEDURE c
13. Return to Section TOC Return to Master TOC Return to Master TOC P 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 cold warm or hot Turn the engine switch to the Start position and crank the engine until it starts slowly return the choke control to the full in position choke open and turn the switch to the Auto Idle LT position Do not turn the switch to the start position while the engine is running because this will cause damage to the ring gear and or starter motor Stopping the Engine Remove all welding and auxiliary power loads and allow engine to run for a few minutes to cool the engine Stop the engine by placing the engine switch in the Off position WARNING Close the fuel valve when the machine is transported to prevent fuel leakage from the carburetor Break in Period It is normal for any engine to use larger quantities of oil until break in is accomplished Check the oil level twice a day during the break in period about 50 run ning hours Change the oil after the first 5 hours of operation See the Engine Instruct
14. 1 SoLENOID ALTERNATOR SOLENOID WINDING BOOST WINDING HOUR METER 2 ENGINE c T SHUTDOWN REPAY OUTPUT o0 cy AUTOMATIC OUTPUT CONTROL 9 IDLER CONTROL CIRCUIT circuit MEE o TT ne CIE ala FIELD CONTROL PC BOARD ENGINE STARTING PROTECTION AND BATTERY CHARGING If the battery is too low to properly power the starter motor the built in recoil starter can be used to crank the engine As long as the battery can produce 6 volts or more the engine ignition system will remain ENGINE STARTING enabled A 12 Volt battery supplies power to the rotary run stop idle switch through a fuse that is located NOTE This machine will only start if there is at least 6 inside the control box There is also a lead running volts available to activate the engine ignition system If eio OJO E f i 0 Q a 5 5 amp Return to Section TOC Return to Master TOC from the fuse to the PC board This is for battery charging only When the switch is placed in the Low Idle or High Idle position a relay on the PC board is activated This relay activates the engine ignit
15. AIR CLEANER With normal operating conditions the maintenance schedule for cleaning and re oiling the foam pre filter is every 50 hours and replacement of the air cleaner filter element every 100 hours More frequent servicing is required with dusty operat ing conditions Refer to the maintenance section of the Engine Owner s Manual for more information OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO i Q amp a gt 5 5 amp Return to Section TOC Return to Master TOC Return to Master TOC udi MAINTENANCE zi To service the pre cleaner Remove the cover Carefully remove the foam pre cleaner from the filter element 1 Wash 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 and reinstall the air cleaner cover and wing nuts CLEAN ENGINE Remove dirt and debris with a cloth or a brush Do not clean with a forceful spray of water Water might contaminate the fuel system Use low pressure air to blow out the machine periodically In particularly dirty locations this may be required once a week SPARK PLUG SERVICE To service spark plug remove the 9 screws securing the side panel Remove side panel and place provi
16. F 2 a PC Board Troubleshooting Procedures F 3 Troubleshooting Guide 44 2444 seek ome rb EEE EE P pe Phebe bee nie F 4 T stiProcedures Dae bad SONS Gadde Pe PS F 13 Engine RPM Adjustment Procedure 1 F 13 Throttle Adjustment Procedure 1 F 17 Brush and Slip Ring Procedure F 19 o o 5 Rotor Flashing and Voltage F 23 o Battery Charging System F 25 stator Voltage Test RET seen dies F 27 Rotor Resistance and Ground Test Static F 29 Rotor Resistance and Ground Test Dynamic F 31 Stator Short Circuit and Ground F 33 Weld Boost System Test F 35 o 9 Case Cover Removal and Replacement Procedure F 37 Fuel Tank and Enclosure Removal and Replacement Procedure F 39 gt 2 Control Box Removal and Replacement Procedure
17. e Return to Section Return to Master TOC o 5 o E 2 E tc ru TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S The engine runs erratically 1 stops running OUTPUT PROBLEMS RECOMMENDED COURSE OF ACTION Check that the fuel valve is fully 1 Check the idle solenoid and open and that there is sufficient fresh gasoline in the tank The choke may be engaged Be sure the choke handle is pushed in completely after the engine has begun to warm up Be certain that the battery is properly connected adequately charged even if using the recoil starter Check the engine oil level Check or replace the fuel filter Check or replace air filter Check spark plug clean or replace if necessary Observe the oil level indicator Perform light while cranking the engine If the light is blinking while cranking the engine the oil level may be low or the oil level system may be faulty Contact the engine manufacturer any additional maintenance suggested in the engine operator s manual engine carburetor linkage for damage excessive dirt or binding If possible perform the engine RPM adjustment Place the engine switch in the stop position unplug engine to welder harness
18. OUTBACK 185 For use with machine code number 11516 Return to Master TOC View Safety Info PEN TD 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 Return to Master TOC View Safety Info 2 gt B z gt 5 o gt 2 E tc SERVICE MANUAL View Safety Info LI NCOLN 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 Return to Master TOC Return to Master TOC Return to Master TOC o 5 o gt 2 E tc Return to Master TOC i SAFETY i CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductive harm The engine exhaust from this product contains chemicals known t
19. Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected ATTENTION to a grounded part of the Static Sensitive auipment frame Devices If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Handle only at Static Safe Workstations Tools which come in contact with the PC board must be either conductive anti static or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag 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 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement P
20. 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 Lincoln Electric offers a welding accessory kit with 6 welding cables See ACCESSORIES of this manual for more information For more information on welding see WELDING OPERATION n the OPERATION section of this man ual 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 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 ge
21. 2 Thoroughly clean the engine crankshaft and the rotor shaft where it mates to the engine crank shaft Place the rotor on the crankshaft 3 When installing rotor thru bolt apply thread locking compound Locktite 2760 or equiva lent torque the rotor thru bolt to 22 to 24 ft lbs 4 After the rotor is secured to the engine crank shaft check the run out at the bearing outer race Run out should not exceed 015 F I M 5 See the stator removal and installation proce dures for further assembly instructions OUTBACK 185 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i Q amp a 5 5 amp Return to Section TOC Return to Master TOC Return to Master TOC F 53 TROUBLESHOOTING AND REPAIR 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 60 VDC Full load test values Weld output control set to maximum Output amps 165 190 Volts 21 27 RPM 3300 3650 Weld output set to minimum Output amps 40 55 Volts 20 28 Auxiliary receptacles with weld output control set to maximum 230 Volt receptacles Load amps 22 25 Volts 216 250 VAC 120 Volt re
22. Disconnect all cables and cords from the weld output terminals and the auxiliary receptacles Check for DC open circuit voltage OCV About 70 to 80 volts at the weld output terminals and check for AC auxiliary voltage at the 120 and 240 VAC receptacles Check that circuit breakers are not tripped RECOMMENDED COURSE OF ACTION 1 Unplug P4 J4 connector and measure the idle solenoid resistance between leads 213B and 215A it should measure about 15 ohms Measure the resistance from lead 213B or lead 215A to chassis ground Resistance should be very high 500 000 500K ohms or higher Replace the solenoid if the resistance is significantly different Reconnect P4 J4 and start the machine placing the engine switch in the high position Plug in a 100 watt light bulb Check for AC voltage at leads 260 J2 3 and 261 J2 4 The meter should read about 1 2 volts If voltage is significantly lower replace the toroidal current transformer the above readings are normal replace the PC board The brushes and slip rings may be worn or faulty Perform the brush and slip ring service procedure With the engine running check for battery voltage at the PC board J3 9 lead 208A If voltage is not present check conductors and connection at leads 208A 208 and the engine wiring leading to the engine charging system If the connections are good the battery charging system may be faulty Conta
23. TOC Return to Section TOC eio OJO E f i 091 c 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 39 TROUBLESHOOTING AND REPAIR FUEL TANK AND ENCLOSURE 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the fuel tank enclosure MATERIALS NEEDED Approved gasoline container and pump 7 16 Wrench Rags Pliers 3 8 Wrench OUTBACK 185 LINCOLN B F 39 Fr TROUBLESHOOTING AND REPAIR FUEL TANK AND ENCLOSURE REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 14 FUEL TANK REMOVAL Return to Section TOC Return to Master TOC FUEL TANK 3 8 SCREWS 3 8 SCREWS Return to Master TOC o o ao
24. b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 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 require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ven tilation In confined spaces or in some circumstances outdoors a respirator may be required Additional pre cautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker expo sure level should be checked upon installation and periodi cally thereafter to be certain it
25. brushes should be replaced if either brush has less than 1 4 remaining before it reaches the end of its travel Spring tension should be suf ficient to hold the brushes firmly against the slip rings The brushes should be removed from the brush holder and be examined The terminals should be clean The shunt braided lead connecting the carbon brush to the terminal should be in good condition and firmly connected to the car bon brush and to the connection terminal If the slip rings are discolored display evidence of excessive sparking or the brushes have worn prematurely these may be signs of a grounded or shorted roter OUTBACK 185 LINCOLN B F 20 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i Q amp a 5 amp Return to Section TOC Return to Master TOC Return to Master TOC F 21 TROUBLESHOOTING AND REPAIR BRUSH AND SLIP RING SERVICE PROCEDURE continued FIGURE F 6 BRUSH REMOVAL AND REPLACEMENT CABLE TIE BRUSHES 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 out put but the machine may also begin to work properly for a short time after being jarred or moved 10 If there is any evidence that the
26. connector P4 J4 located inside the control box at the bottom left CAUTION Disconnecting this plug disables the normal engine shut down function of the engine switch Reconnect 4 4 to shut the engine down Attempt to start the engine using the recoil starter If the problem persists check for faulty insulation at the brown and brown white wires connecting P4 J4 to the engine magneto If the insulation is good contact a qualified engine repair technician If the engine runs normally with P4 J4 disconnected check for battery voltage between J3 10 4 and J1 2 If the voltage is low or erratic check conductors and connections at GND G lead 211 lead 209A and lead 230 Check the fuse fuse holder and the engine switch Replace or repair any defective leads or components If the voltage between J3 10 and J1 2 is normal check for defective insulation on lead 212 If insulation is good replace PC board A CAUTION 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 OUTBACK 185 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e c 42 Return to Section TOC Return to Master TOC o 5
27. flathead screw turn the high idle adjustment screw See Figure F 4 Turning the screw clockwise will increase RPM and turning it counterclockwise will decrease the RPM Engine high idle RPM should be between 3700 and 3800 RPM the low idle adjustment screw See Figure F 4 The low idle RPM should be between 2250 and 2500 RPM OUTBACK 185 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i c a 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 19 TROUBLESHOOTING AND REPAIR BRUSH AND SLIP RING SERVICE 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 PROCEDURE DESCRIPTION This procedure provides guidance in testing and maintaining the brush and slip ring sys tem MATERIALS NEEDED 500 or 600 grit emery
28. ground connec tion Restart the engine and run it at high idle speed The resistance should be very high at least 500 000 500k ohms If the resistance readings differ significantly from the values indicated re check the brushes and the brush spring tension the brushes and slip rings are good replace the rotor Re attach the brush leads and install the brush cover NOTE The resistance of the copper windings will change the temperature Higher temper atures will produce higher resistance and lower temperatures will produce lower resistance OUTBACK 185 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i c a 5 5 amp c Return to Section TOC Return to Master TOC F 33 TROUBLESHOOTING AND REPAIR 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting ass
29. hot metal surfaces and live electrical devices STORING 1 Store the machine in a cool dry place when it is not in use Protect it from dust and dirt Keep it where it can not be accidentally damaged from construction activities moving vehicles and other hazards 2 f you will be storing the machine for over 30 days you should drain the fuel to protect fuel system and carbure tor parts from gum deposits Empty all fuel from the tank and run the engine until it stops from lack of fuel 3 Youcan store the machine for up to 24 months if you use a stabilizing Additive in the fuel system Mix the additive with the fuel in the tank and run the engine for a short time to circulate the additive through the carburetor 4 While the engine is still warm drain the oil and refill with fresh 10W30 oil 5 Remove the spark plug and pour approximately 1 2 ounce 15ml of engine oil into the cylinder Replace the spark plug and crank the engine slowly to distribute the oil 6 Clean any dirt and debris from the cylinder and cylinder head fins and housing rotating screen and muffler areas 7 Store in a clean dry area OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio EM 091 amp a gt 5 amp Return to Section TOC Return to Master TOC Return to Master TOC INSTALLATION Bt STACKING OUTBACK 185
30. is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 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 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 Also see item 1 b OUTBACK 185 LINCOLN B Return to Master TOC Return to Master TOC o 5 o gt 2 E tc Return to Master TOC SAFETY gt WELDING and CUTTING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area lf 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 Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to pr
31. it should not fall below 3300 RPM Read the DC voltage at the output terminals If the voltage is between 21 and 27 the boost sys tem is functioning normally If the weld terminal voltage is low Shut off the engine and perform the Case Cover Removal Procedure 10 11 12 13 14 TOP VIEW OF ENGINE Start the engine and apply a load of about 80 to 100 Amps Check for AC voltage between leads 13 and 14 at the PC board See wiring diagram If voltage is present rotate the output control knob and observe the voltage between leads 13 and 14 The voltage should rise and fall as the output control is moved If the voltage at leads 13 and 14 is responding as described above the PC board is probably defective If no significant voltage is detected at leads 13 and 14 and if the voltage does not respond to changes to the output control knob setting check for a defective CB4 circuit breaker Check for poor connections or damaged wires at leads 13 13A and 14 If the breaker and wires are good the reactor is likely defective OUTBACK 185 LINCOLN B F 36 Psi TROUBLESHOOTING AND REPAIR Ew 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 yo
32. may be low or defective Return to Section TOC Return to Master TOC The welding electrode may be wet or contaminated Try using a fresh dry welding electrode Return to Section TOC Return to Master TOC eio OJO gt 091 amp a 5 5 amp 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 Return to Section TOC Return to Master TOC OUTBACK 185 LINCOLN B F 12 NOTES OUTBACK 185 LINCOLN F 12 DOL 19159 01 DOL J8ISEN 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i c a 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 13 TROUBLESHOOTING AND REPAIR F 13 ENGINE RPM 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
33. plug is tight after servicing FUEL Bi Fill the fuel tank with clean fresh regular grade mini mum 87 octane lead free gasoline DO NOT MIX OIL WITH GAS The OUTBACK 185 capacity is approxi mately 6 8 gallons 25 74 Liter DO NOT OVERFILL allow room in the fuel tank for fuel expansion SPARK 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 K2793 1 CAUTION An incorrect additional arrester may lead to dam age to the engine or adversely affect performance nr agpiaaicn GASOLINE FUEL ONLY ra injure OUTBACK 185 LINCOLN 5 dd INSTALLATION pes OUTBACK 185 OUTPUT CONNECTIONS ojo 212 ols a 6 212 c c 5 5 2 8 o O15 E 8 212 9 8 a 212 ala 2 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 ojo ELECTRICAL OUTPUT CONNECTIONS TABLE A 1 5 5 RECOMME
34. receptacle A 50 amp 240 volt single outlet receptacle See Figure A 1 Through these receptacles the machine can supply up to 5700 watts surge or 5200 watts continuous of single phase 60 Hertz AC power The machine output volt ages meet UL standards and fall within 10 of the rated voltage PREMISES WIRING The 185 is not recommended for premis es wiring The OUTBACK 185 does not have a com bined 120 240 volt receptacle and cannot be connect ed to a premises as described in other Lincoln litera ture The 185 is intended only for backup intermittent use power Certain electrical devices can not be powered by the OUTBACK 185 Refer to Table A 2 for these devices CIRCUIT BREAKERS gt Auxiliary power is protected by circuit breakers When the machine is operated in high temperature environ ments the breakers may tend to trip at lower loads than normally CAUTION NEVER BYPASS THE CIRCUIT BREAKERS WITH OUT OVERLOAD PROTECTION THE UNIT COULD OVERHEAT AND OR CAUSE DAMAGE TO THE EQUIPMENT BEING USED OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO gt 091 c a 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC INSTALLATION CAUTION Certain Electrical devices cannot be powered by the OUTBACK 185 See Tabl
35. stud and lead W3 or W4 This checks for a connection between the auxiliary power winding and the other weld winding d Lead 7 and lead W1 or W2 This checks for a connection between the exciter wind ing and one of the weld windings Lead 7 and lead W3 or W4 This checks for a connection between the exciter wind ing and the other weld winding If any of the above readings is less than 500 000 500 ohms check for damaged contaminated or shorted wiring or defective components connected to the stator windings necessary disconnect and isolate leads as close to the stator winding as possible See Wiring Diagram If the low resis tance is determined to be between the windings within the stator the stator is defective and should be replaced OUTBACK 185 LINCOLN 5 F 34 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i c a 5 5 amp c Return to Section TOC Return to Master TOC F 35 WELD BOOST SYSTEM TEST 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 m
36. the largest loads first TABLE B 2 ELECTRODE SELECTION GUIDE CLASSIFICATION ELECTRODE TYPE FLEETWELD 5P FLEETWELD 35 FLEETWELD O 180 FLEETWELD 37 EXCALIBURO 7018 JETWELD LH 73 SOFTWELD 99Ni WEARSHIELD ABR e SHEET THICKNESS DC BLUE MAX 308 308L AC DC DC amp k CURRENT RANGE AMPS ELECTRODE 3 32 SIZE 1 8 SIZE 50 75 5 32 SIZE 90 175 80 145 105 135 145 180 125 185 130 185 95 150 100 140 50 185 75 135 70 110 55 110 100 135 90 125 90 125 75 110 80 110 50 150 1 8 AND THINNER 1 8 AND THICKER OUTBACK 185 LINCOLN 5 Le OPERATION olo TABLE B 3 AUXILIARY POWER APPLICATIONS 5 5 8 5 Suggested Power Applications Running Watts Start up Watts ole Continuous Peak Air Compressor 1 HP 2 000 4 000 8 000 Air Compressor 3 4 HP 1 250 3 100 5 000 Airless Sprayer 1 3 HP 600 1 500 2 400 Chain Saw 1 200 Circular Saw 1 200 Coffee Maker 1 000 Deep Freezer 500 750 2 000 Electric Motor 1 HP 1 000 2 500 4 000 Electric Range 1 element 1 500 5 Electric Skillet 1 250 E E Furnace Fan 1 3 HP 1 200 3 000 4 800 Portable Grinder 4 1 2 600 i ne Portable Grinder 7 2 000 Halogen Work Light 500 cc Hand Drill 1 4 500 Hand Drill 3 8 700 1500 Watt Heater 1 750 Hedge Trimmer 450 Light B
37. to Master TOC LINCOLN amp ELECTRIC SCHEMATIC COMPLETE MACHINE CODE 11516 G6205 ENGINEERING CONTROLLED CHANGE DETAIL RELEASED A 02 FROM X MANUFACTURER No ELECTRICAL DIAGRAMS insulated inline connectors lop engine area BW near LED indicates 9 connections 4 places 11 900 5 6B GND E a B IE 5 Rapa TUS RECTION 12 Di der front under front edge front top left of control box LEFT BOTTOM AC REACTOR both top front lt 90 Ie we MAY OPEN IF MACHINE 5 13A Pos brush is closest to lamination Sohms SLIP OVERLOADED 30 min to 50 VDC max RINGS ANDER Boost Coils bera e CONTROL Used to supply bd under front edge edid BOX power during of control box RIGHT 1 2 volts 55 HZ ise in short 9 Hi rpm with a100W bulb conditions on 115 aux 260 261 6v in 72 no load 26mV FLASH CURRENT PATH J2 3 2 4 SUPPRESSOR FOR D1 RECTIFIER J1 12 LOW OIL Y 10 VOLT REGULAT RED name pl
38. your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION Test will determine whether the engine is operating at the correct speed RPM during both HIGH and LOW idle conditions MATERIALS NEEDED Miscellaneous hand tools and metric wrench set High visibility marker Strobe tach frequency counter or vibratach OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 0 Q a 21e 5 5 gt amp c Return to Section TOC Return to Master TOC Return to Master TOC F 14 TROUBLESHOOTING AND REPAIR F 14 ENGINE RPM ADJUSTMENT PROCEDURE continued FIGURE F 1 STROBE TACH METHOD PROCEDURE Strobe Tach Method 1 2 Turn the engine off 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 Connect the strobe tach according to the man ufacturer s instructions Start the engine and place the idle switch in the HIGH IDLE position Make sure that there is no loa
39. 185 LINCOLN 5 ____ TABLE OF CONTENTS OPERATION SECTION o 9 Operation coussins De abe ta oe DE UE AE i SIUE B 1 gt 2 c 5 Safety INStructions iu solere ber eris ewe emu a pee c QW TOE bee B 2 a SYMPBOIS sae seed _ _ B 3 General Description 2 i wiae beu a nexo RR DPA PER ep p B 4 Recommended Applications B 4 Operational Features and Controls B 4 Design Features Advantages 1 B 4 Welding Capability ss ed ire tear reor road pa gee ceeds yan sde V pad ro B 4 o o 9 T E LIMRATIONS ii ccc B 4 o Controls and Settihgs 2124 usauetphe etant puce mnt FAUNE PERE eee SE Ee 5 Welder Generator Controls 5 Engine Op ration hu deu rre e ien PEL B 6 Welding Operation Ren Rx Xe Seb NU OE ewe xod B 7 Auxiliary POWER esere dues menthe EXE REG ck px Peu ee hU E EP ee B 8 Electrode selection Guide 1 B 8 Auxiliary Power App
40. 30 volts See wiring diagram Check for AC voltage between leads W1 and W2 See Wiring Diagram Voltage reading should be about 64 VAC Also check for AC voltage between leads W3 and W4 Voltage reading should be about 62 VAC See wiring digram If the voltage is not present or is significantly dif ferent from expected readings check the wiring between test points and the stator winding See wiring diagram If the wiring is in good condi tion the stator is defective Voltage shown is for a stator that is at normal full load temperature Readings will likely be slightly higher if machine is cold OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i c a 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 29 TROUBLESHOOTING AND REPAIR F 29 ROTOR RESISTANCE AND GROUND TEST STATIC 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs
41. 4 ete Ave eae oP ee A 4 Iuno mc A 4 Pre Operation Engine Service 4 mE 4 Fuel aac ceca de tae peed aed Kock c RER ed a itu LME 4 Spark AIrester stes 1 Pees Peele 4 Electrical and Welding Connections 1 A 5 Machine Grounding pete emu rea beue thus dos A 6 Plugs and Hand Held Equipment Auxiliary Power Receptacles A 7 Premises Wirlng oper Deus du Das ELE pate net A 7 Circuit Breakers ein Ad RO uk eee A 7 Electrical Devices used with the OUTBACK 185 A 8 OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC A 2 INSTALLATION TECHNICAL SPECIFICATIONS OUTBACK 185 K2706 1 Make Model KOHLER CS 12 75 Description 1 cylinder 4 cycle air cooled OHV gasoline 12 75 HP 3600 RPM Aluminum Block INPUT GASOLINE ENGINE Speed RPM 3750RPM High Idle 1825RPM Low Idle 3400RPM Full Load Displacement 21 96 cu in 360 cc Bore x Stroke 3 35 x 2 48 85 mm x 63mm Ignition System Electric amp Recoil Start Manual Choke Capacities Fuel 6 86 gal 24
42. 9L Oil 1 2 Qts 1 1L w Cast Iron Sleeve RATED OUTPUT WELDER 100 130 150 185 100 60 20 MAX OUTPUT Return to Section TOC Return to Master TOC OUTPUT WELDER AND GENERATOR Welding Ranges Welding Open Circuit Voltage AC Auxiliary Power 4600 Watts 115V 1PH 100 Duty Cycle 5700 Peak Watts 5200 Continuous Watts 120 230 V 1PH 50 185 Amps DC 80 VDC Max PHYSICAL DIMENSIONS HEIGHT WIDTH WEIGHT 25 47 in 21 12 in 310 0 Ibs 646 94 mm 536 45 mm 140 6 kg o 5 o E 2 E tc c OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 0 F TO 104 F 18 C TO 40 C 40 F TO 131 F 40 C TO 55 C Return to Section TOC Return to Master TOC OUTBACK 185 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio gt Oo amp a gt 5 5 amp c Return to Section TOC Return to Master TOC RS 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 instructio
43. A 2 ELECTRICAL DEVICE USE WITH THE OUTBACK 185 in the section of this manual GENERAL INFORMATION The 185 is rated at 5700 Peak watts or 5200 continuous watts It provides both 120 volt and 240 volt power You can draw up to 20 amps from either side of the 120 volt duplex receptacle but not more than 35 4 amps from both sides at once Up to 17 7 amps can be drawn from the single 240 volt receptacle Electrical loads in watts are calculated by multiplying the voltage rating of the load by the number of amps it draws This information is given on the load device nameplate For example a device rated 120 volts 2 amps will need 240 watts of power 120 x 2 240 You can use Table 3 AUXILIARY POWER APPLI CATIONS to determine the wattage requirements of the most common types of loads you can power with the OUTBACKO 185 Be sure to read the notes at the bottom of the table TO USE THE OUTBACK 185 AS AN AUXILIARY POWER SUPPLY 1 Start the gasoline engine See ENGINE OPERA TION in this section of the manual 2 Set the current control dial on the output control panel to MAX See Figure B 1 3 Plug the load s into the appropriate 120 volt or 240 volt power receptacle NOTE During welding the maximum generator out put for auxiliary loads is 100 watts NOTE You can supply multiple loads as long as the total load does not exceed 5700 Peak watts or 5200 continuous watts Be sure to start
44. AND VOLTAGE TEST 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if correct voltage is being applied to the rotor slip rings MATERIALS NEEDED Misc hand tools Multimeter OUTBACK 185 LINCOLN B F 23 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i c gt 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 24 TROUBLESHOOTING AND REPAIR 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 Ensure that there is no load on either the weld or auxiliary outputs 3 Set the output control to maximu
45. BACK 185 LINCOLN B D 5 6 5 gt 5 v VA 7 lt 5 Y 3 eg mum u uU 2992 1942 AER 20 m OW 32555 2 d d om DOL ISEN OL Je1se A DOL DOL ISEN JOL uonoe 1295 uinjeg 3 uonoes oi JOL uonoe 109 uunjed JOL uonoe 5 D 6 NOTES OUTBACK 185 LINCOLN D 6 DOL 19159 01 DOL J8ISEN 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Master TOC Return to Master TOC o 5 o gt 2 E tc Return to Master TOC E TABLE OF CONTENTS THEORY OF OPERATION SECTION Theory of Operation OC rrern E 1 Engine Starting Protection and Battery Charging E 2 E 3 Automatic Idle System 2 23 1e IEEE pec RC ER eA eee E 4 Generating POWeTr 2 puce Ee OWN iR ed te d Ven E 5 E 6 FIGURE E 1 BL
46. C board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO E f i 091 amp a gt 5 5 amp c Return to Section TOC Return to Master TOC i TROUBLESHOOTING AND REPAIR RECOMMENDED COURSE OF ACTION Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S OUTPUT PROBLEMS Major physical or electrical Contact the Lincoln Electric damage Service Department at 1 888 935 3877 The engine will not crank while 1 Be certain that the battery is using the electric start function pr
47. DESCRIPTION This procedure will aid the technician in the removal and replacement of the rotor MATERIALS NEEDED Rotor Puller Tool See parts pages for the tool part number Impact Wrench OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO E f i 091 amp 5 5 amp Return to Section TOC Return to Master TOC Return to Master TOC F 52 TROUBLESHOOTING AND REPAIR F 52 ROTOR REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 21 ROTOR LOCATION THROUGH BOLT PROCEDURE Perform the Stator Removal Procedure Remove the long through bolt from the bearing end of the rotor An impact wrench works best for removing this through bolt See Figure F 21 Remove the rotor from the engine crankshaft using the Lincoln rotor pulling tool See instruc tions supplied with the tool IMPORTANT Handle and store the rotor very carefully to avoid damage to the windings If necessary the cast end bracket can now be removed from the engine Replacing the Rotor 1 If the cast end bracket had been removed from the engine clean the mating surfaces and rein stall it on the engine at this time Bolts should be tightened to a torque of 22 to 24 ft lbs IMPORTANT It is highly recommended that a new bearing be installed before the rotor is secured to the engine crankshaft
48. ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside SN Do not stack anything on or near the engine MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts Only qualified personnel should install use or service this equipment The OUTBACK 185 can deliver from 50 to 185 amps of welding output current Output can be adjusted by setting the current control dial on the out put control panel You can get maximum welding output by setting the dial to 185 AMPS At high current settings like this some output may decrease as the machine is used If you are welding for a long time you may need to turn the dial slightly upward to maintain the same results The numbers on the dial correspond to the approxi mate amps needed to weld using specific Lincoln welding rods WELDING APPLICATIONS give you the recommended dial settings based on the thickness of the work and the size and type of rod you re using TO USE THE OUTBACK 185 FOR WELDING 1 Remove the flange nuts from the weld output ter minals and place the work and electrode welding cables over the terminals See Figure B 1 and B 1a Replace and tighten the flange nuts securely Be sure the connections are tight 2 Select the appropriate electrode See Table B 2 3 Attach the work clamp securely to the work you are weldin
49. EPTACLES 2 Connection point for supplying 120 volt power to operate devices needed for maintenance purposes 11 ENGINE CHOKE Engine starting aid 12 ENGINE SWITCH Used to start the engine Select High Idle or Auto Idle while the engine is running and stops the engine When placed in the OFF circuit is de energized to shut down the engine position the ignition When held in the START position the engine starter motor is energized When in HIGH IDLE position the engine will run continuously at high idle When in AUTO IDLE n AY position the engine will run continuously and the idler operates as follows Welding When the electrode touches the work the welding arc is initiated and the engine accelerates to full speed After welding ceases and no auxiliary power is being drawn the engine will return to low idle after approximately 10 to 14 seconds Auxiliary Power With the engine running at low idle and auxiliary power for lights or tools is drawn approximately 0 150 watts or greater from the receptacles the engine will accelerate to high speed If no power is being drawn from the receptacles and not welding for 10 14 seconds the idler reduces the engine speed to low idle OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio gt 091 a gt 5 5 amp
50. LE 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 high and auto positions on the rotary run stop idle switch control the supply of positive battery voltage to the idle solenoid When the switch is in the high position the solenoid is shut off and the engine will remain in high idle When the switch is in the auto position positive battery voltage is applied to the solenoid and the negative connection is controlled by the PC board as described below The following explanation assumes that the rotary Switch is in the auto position and the engine is oper ating at low RPM Weld and auxiliary current are detected by a toroidal current sensor that is connected to the PC board When sufficient current flows through the sensor the PC board detects this and immediately interrupts the negative connection to the solenoid The solenoid is released and the engine RPM increases to the high setting When the current flow stops the PC board will begin a time delay of about 12 seconds If the current flow begins again during this time delay the solenoid remains inactive and the engine continues to operate at high RPM If no current flow is detected at the end of the 12 second delay t
51. NDED WELDING CABLE Figure A 1 for the location of the current control SIZE AND LENGTH o dial weld output terminals ground stud circuit break ers 240 and 120 volt receptacles TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES 5 WELDING CABLE CONNECTIONS Cable 125 Amps Length 30 Duty Cycle Cable Size and Length 0 50 ft 0 15m 6 AWG Be sure to use welding cables that are large enough The correct size and length becomes especially impor 50 100 ft 15 30 m tant when you are welding at a distance from the welder 100 150 ft 30 46 m Table A 1 lists recommended cable sizes and lengths for rated current and duty cycle Length refers to the dis 150 200 ft 46 61 m tance from the welder to the work and back to the welder Cable diameters are increased for long cable 200 250 ft 61 76m lengths to reduce voltage drops Return to Section TOC Return to Master TOC OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i a 5 5 amp c Return to Section TOC Return to Master TOC A 6 Cable Installation INSTALLATION A 6 MACHINE GROUNDING Install the welding cables to your OUTBACK 185 as follows See Figure A 1 the location of parts 1 The gasoline engine must be OFF to install weld ing cables 2 Remove the 1 2
52. OCK LOGIC DIAGRAM SENSOR 120 VAC RECEPTACLES LAC OIL LEVEL LY INDICATOR 5 5 fee x ES MODULE 082 S84 D REACTOR E d AUXIIARY WINDINGS OIL LEVEL SWITCH STATOR WELD OUTPUT WINDINGS RECTIFIER OUTPUT 2 PHASE STUDS ENGINE STARTER EXCITER IDLE SOLENOID SOLENOID ALTERNATOR WINDING BOOST WINDING BATTERY ENGINE SHUTDOWN OUTPUT AUTOMATIC OUTPUT CONTROL IDLER CONTROL CIRCUIT CIRCUIT FTT rh HOUR METER FIELD CONTROL PC BOARD OUTBACK 185 LINCOLN B ET THEORY OF OPERATION FIGURE E 2 ENGINE STARTING PROTECTION AND BATTERY CHARGING e CURRENT 120 VAC RECEPTACLES 240 SENSOR RECEPTACLE cls gt 6 26 Ee OIL LEVEL I OIL INDICATOR cer o gt LEVEL S ils Taxe a MODULE 285 olo KOHLER REACTOR EL gt OIL LEVEL AUXIIARY WINDINGS swrrcH sup STATOR 5 RINGS 8 ARR OUTPUT E IGNITION ENGINE ROTOR WINDINGS RECTIFIER OTO EY 2 PHASE STUDS BRUSHES FA STARTER IDLE EXCITER
53. Procedure 10 Cut cable ties as needed and disconnect these wires 11 Remove any remaining 3 8 screws from left 12 13 side of the control box and gently lift the con trol box off the generator assembly Reverse the above procedure to reassemble Replace any cable ties removed during disas sembly OUTBACK 185 LINCOLN 5 nds TROUBLESHOOTING AND REPAIR ps CONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 17 BATTERY LOCATION Return to Section TOC Return to Master TOC MOUNTING BRACKET Return to Section TOC Return to Master TOC BATTERY eio OJO f i Q a 21e 5 5 gt amp Return to Section TOC Return to Master TOC OUTBACK 185 LINCOLN B F 46 NOTES OUTBACK 185 LINCOLN F 46 DOL 19159 01 DOL J8ISEN 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i c a 5 5 amp c Return to Section TOC Return to Master TOC F 47 TROUBLESHOOTING AND REPAIR nc STATOR REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory t
54. SYMPTOMS MISADJUSTMENT S OUTPUT PROBLEMS Continued No 115 230 VAC auxiliary output 1 Check for faulty extension Weld output is normal and engine cords tools lights etc Plug in operates normally a known working device 2 Check for breakers tripped circuit 3 If the Outback has optional GFCI receptacles try resetting them NOTE Engine must be running at high idle RPM or the GFCI receptacles will not reset 1 The output control may be set too low Low weld and auxiliary output the engine operates normally 2 Engine RPM may be low 3 The battery may be faulty TROUBLESHOOTING AND REPAIR RECOMMENDED COURSE OF ACTION F 10 4 With the engine still running check for about 70 to 80 VDC at the output rectifier positive and negative terminal If voltage is not present the rectifier is probably faulty If the is voltage at the rectifier output but not at the weld terminals the choke may be open Check for AC voltage at the back of the receptacles voltage is present at the back of the receptacles but the receptacles still will not function replace the receptacle Check for 120 VAC from lead 5 to leads 3 and 6 at the circuit breakers See wiring diagram If 120 VAC is present one or more circuit breakers may be defective If AC voltage is not detected in step 2 above check leads between the test points and the stator winding If the leads are good the stator
55. ad been disconnected from the neutral stud This tests for a grounded auxiliary winding b The 77 or 49 lead This tests for a ground ed exciter winding c W1 or W2 lead This tests for a grounded weld winding d W3 lead This tests for a grounded weld winding If any of these readings are less than 500 000 500 ohms check for grounded components or wiring that remain connected to the stator such as circuit breakers receptacles output rectifier reac tor etc See Wiring Diagram necessary dis connect and isolate the stator leads as close to the stator winding as possible If the low resistance to ground is determined to be in the stator windings the stator is defective and should be replaced 7 If the stator is not grounded check for short cir cuit connections between the windings that should be isolated from each other 8 Using ohmmeter check the resistance between the following points Resistance should red very high 500 000 500k ohms min imum a The 5 lead that had been disconnected from the neutral stud and either lead 7 or lead 9 This checks for a connection between the auxiliary power winding and the excited winding b The 5 lead that had been disconnected from the neutral stud and lead W1 or W2 This checks for a connection between the wire auxiliary power winding and one of the weld windings c The 5 lead that has been disconnected from the neutral
56. ains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA p
57. and 224A Check the positive terminal connections at the hour meter 5 Check that the PC board is properly grounded pin J1 2 lead GND G 6 Perform the rotor flashing voltage and resistance tests 7 Perform the and voltage tests Check for loose or damaged connections between the output terminals the choke the rectifier the rector and the stator See wiring diagram With engine running at high idle and output control set to maximum check for about 63 VAC from each of the two stator weld windings W1 to W2 and W3 to W4 See wiring diagram If voltage is not present for either test the stator is probably defective With the engine still running check for about 63 VAC at W1A to W2 and from W3A to WA f voltage is not present for either test the reactor may be defective If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely OUTBACK 185 LINCOLN B contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e c Return to Section TOC Return to Master TOC o 5 o E 2 E tc F 10 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF
58. anual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test checks the functionality of the weld boost system This test should be done if the weld terminal open circuit voltage and engine RPM are normal but the machine weld output is low MATERIALS NEEDED Resistive load bank Misc hand tools Multimeter OUTBACK 185 LINCOLN B F 35 TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i Q amp a 5 5 gt amp c Return to Section TOC Return to Master TOC Return to Master TOC F 36 LOW IDLE ADJUSTMENT TROUBLESHOOTING AND REPAIR WELD BOOST SYSTEM TEST continued FIGURE F 12 HIGH AND LOW IDLE ADJUSTMENT HIGH IDLE ADJUSTMENT PROCEDURE Check that the CB4 circuit breaker is not tripped 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 the engine switch in the High idle position Verify that the engine RPM is correct See the Engine RPM adjustment procedure Turn on the load bank and adjust to get a 165 to 190 Amp load Check engine RPM
59. ate area inside control box bottom left Kohlers part CIRCUIT 1 magneto type SOLENDID 210B 2 2 208 board power 3 lt 213B 4 lt 215A 5 IDLE 15 ohms 12 voltdc_ RW 1 IGNITION 0085 top left rear engine Energized for LOW idle spring on solenoid to hi LECO part left side engine OL LEVEL SENSOR d CLOSED WHEN l OIL LEVEL IS TOO LOW Air filter left front intake is on backside of filter asbly Al engine components are inside the engine housing SEE SOLENOID DETAIL BELOW 230 6 There is an extra fuse si with the fuse holder N FUSE 209A 10 amp 12vdc sl T 10V LOAD IDLE TIMER under white cover HIGH back of control box 12 209 START VOLT BATTERY left front panel front bottom right Battery MUST be gt 6 to use pull start cord If removed gone lt 6vdc engine will not start with pull cord reason CR 1 relay does not pull in on board GND Engine parts are fromKohler Engine muffleris located in the middle RIGHT side area Engine oil fill check drain LEFT or RIGHTsides low on engine The black oil cover is fill
60. ative for more details Plasma Cutting with Lincoln Pro Cut 25 The 185 generator power can be used to supply up to 5 200 watts continuous input power to a Pro Cut 25 The Pro Cut will work satisfactorily under the fol lowing conditions 1 Set the Current Control on the OUTBACK 185 to the 185 amp position Higher Settings may result in a shutdown of the Pro Cut 25 2 Leave the ON OFF switch on the Pro Cut OFF until the OUTBACK 185 has been started and is at full operating speed OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 0 Q a 5 amp Return to Section TOC Return to Master TOC Return to Master TOC idis OPERATION ES 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 The Pro Cut 25 may be used for its full range of con trol Maximum material thickness that can be cut is 3 8 AUXILIARY POWER OPERATION WARNING Be sure that any electrical equipment plugged into the generator AC power receptacles can withstand a 10 voltage and a 5 frequency variation Some elec tronic devices cannot be powered by the OUTBACK 185 Refer to Table
61. brushes may have been sticking in the brush holders a new brush holder and brush assembly should be installed Cleaning Slip Rings 1 In the event that the slip rings have become dirty discolored or mildly pitted it will become necessary to clean them using very fine 500 or 600 grit emery cloth or a 220 or 320 grit com mutator stone 2 Use low pressure compressed air to thoroughly blow the carbon commutator stone and sand paper dust from the machine before operating To install the brush holder assembly push the brushes into the brush holder assembly and place a plastic cable tie through the holes pro vided See Figure F 6 Slide the brush holder assembly back into the generator and secure with the two screws removed earlier Reattach the leads and remove the cable tie Replace the plastic gen erator cover OUTBACK 185 LINCOLN B F 21 F 22 NOTES OUTBACK 185 LINCOLN F 22 DOL 19159 01 DOL J8ISEN 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i c a 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 23 TROUBLESHOOTING AND REPAIR ROTOR FLASHING
62. ce and the work com plete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equip ment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob lems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment b radio and television transmitters and receivers C computer and other control equipment d safety critical equipment e g guarding of industrial equipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement 9 the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h the time of day that welding or other activities are to be carried out OUTBACK 185 LINCOLN B
63. cedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test determines if the stator is producing the correct voltage from each of the wind ings This test should be performed if rotor voltage is normal but one or more of the out put voltage readings are incorrect MATERIALS NEEDED Miscellaneous hand tools Wiring diagram Multimeter OUTBACK 185 LINCOLN B F 27 TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 0 Q gt 212 cre 5 5 amp Return to Section TOC Return to Master TOC Return to Master TOC F 28 F 28 TROUBLESHOOTING AND REPAIR STATOR VOLTAGE TEST continued FIGURE F 9 HIGH AND LOW IDLE ADJUSTMENT HIGH IDLE ADJUSTMENT LOW IDLE ADJUSTMENT TOP VIEW OF ENGINE PROCEDURE 1 Verify that the engine RPM is normal See the Engine RPM Adjustment Procedure Start the machine and place the idle switch in the high position See Figure F 9 Check for AC voltage between the neutral stud on the control panel bottom and the 3 lead connection at the CB1 circuit breaker Also check the voltage between the neutral stud and the 76 lead connection at the CB1 circuit break er Voltage should read between 115 and 1
64. ceptacles Load amps 20 2 24 Volts 108 180 VAC NOTE Values shown above are for a machine that is at normal full load temperature Readings will likely be slightly higher if machine is cold OUTBACK 185 LINCOLN B F 54 NOTES OUTBACK 185 LINCOLN F 54 DOL 19159 01 DOL J8ISEN 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Gri TABLE OF CONTENTS DIAGRAM SECTION ol o Electrical 2 xr G 1 5 g Wiring Diagram Complete Machine Code 11516 113878 G 2 a Schematic Complete Machine Code 11516 06205 G 3 Schematic Field Control Idle PC Board G4793 1 G 4 NOTE Many PC Board Assemblies are now totally encapsulated surface mounted and or multi lay ered and are therefore considered to be unserviceable Assembly drawings of these boards are no longer provided Return to Master TOC o 5 o gt 2 E t Return to Master TOC OUTBACK 185 LINCOLN B G 2 WIRING DIAGRAM COMPLETE MACHINE CODE 11516 L13878 ELECTRICAL DIAGRAMS G 2 WIRING DIAGRAM OUTBACK 185 Return to Section TOC Return to Master TOC
65. cloth 220 or 320 grit commutator stone Optional Needlenose Pliers 1 4 Nut Driver OUTBACK 185 LINCOLN B F 19 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i Q a 21e 5 5 gt amp Return to Section TOC Return to Master TOC Return to Master TOC F 20 LOCKING TABS TROUBLESHOOTING AND REPAIR BRUSH AND SLIP RING SERVICE PROCEDURE continued FIGURE F 5 BRUSH HOLDER ASSEMBLY LOCATION BRUSH HOLDER ASSEMBLY SCREWS 2 COVER PROCEDURE 1 Remove the brush cover from the end of the generator Pry outward at the top of the plastic brush cover while depressing the two locking tabs at the sides of the cover See Figure F 5 3 Remove the brush and brush holder assembly 4 Use needle nose pliers to remove the leads from the brush terminals and then use the 1 4 nut driver to remove the two screws holding the brush holder in place The brush holder assem bly can now be pulled straight out from the end of the generator toward the front of the machine Examine brushes and slip rings The slip rings brush holder and brushes should be clean and free from oil or grease The brushes should be making good continuous contact with the slip rings GENERATOR END BRACKET 6 The brushes should be of sufficient length and have adequate spring tension Generally the
66. ct a qualified engine repair technician 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 OUTBACK 185 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC c Return to Section TOC Return to Master TOC 5 o E 2 E tc Continued There is no weld output or weld voltage drops dramatically when trying to strike an arc The 115 230 VAC auxiliary output is normal engine operates normally OUTPUT PROBLEMS 1 Check weld cables connections work clamps and electrode holder With engine running at high idle and output control set to maximum check the DC voltage at the weld output terminals It should measure 70 to 80 Volts RMS TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION 3 If voltage is present at 9 check for battery voltage at J3 8 lead 224A If voltage is not present replace the PC board 4 If voltage is present at J3 8 check for battery voltage at J1 9 lead 7224 If voltage is not present check leads 224
67. cular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and position e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the con nection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of other cables and
68. d on the machine Direct the strobe tach light at the mark and syn chronize the strobe tach The tach should read between 3700 and 3800 RPM FAN BLADE STROBE TACH MARK 7 Move the idle switch to the AUTO IDLE posi tion and wait for the idle solenoid to energize The engine RPM should drop and stabilize at the low idle RPM 8 Synchronize the strobe tach to read the low idle RPM 9 The tach should read between 2250 and 2500 RPM 10 If either of the readings is incorrect proceed to the Throttle Adjustment Procedure this section OUTBACK 185 LINCOLN 5 rs TROUBLESHOOTING AND REPAIR pas ENGINE RPM ADJUSTMENT PROCEDURE continued olo ele 5 5 FIGURE F 2 FREQUENCY COUNTER METHOD 9 8 o ele HE Solenoid amp Fuel Electric Fuel Pump Engine codes 10926 amp 11121 only 7 Engine Speed Control Lever olo c a o QJ H 5 5 amp c Swivel Fitting MOVING ENGINE SPEED CONTROL LEVER 3 INCREASE DECREASE RPM RPM ojo Frequency Counter Method 2 NOTE A dedicated frequency counter can be 4 Move the idle switch to the AUTO IDLE posi 8 3 used for this test but many high qua
69. ded fiber spacer between the muffler and bottom of control panel See Figure D 2 FIGURE D 2 ENGINE ADJUSTMENTS WARNING OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3750 RPM no load Do NOT tamper with the governor components or setting or make any other adjustments to increase the maximum speed Severe personal injury and damage to the machine can result if operated at speeds above maximum Adjustments to the engine are to be made only by a Lincoln Service Center or an authorize Field Service Shop SLIP RINGS CAUTION A slight amount of darkening and wear of the slip rings and brushes is normal Brushes should be inspected when a general overhaul is necessary If brushes are to be replace clean slip rings with a fine emery paper 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 63 083 19 S 63 083 17 S Champion RC 12YC Gap 030 76mm Air Filter Element Air Filter Pre Cleaner Spark Plug Resistor Type OPERATIONAL CLEARANCE CAUTION Approximately 12 18 of clearance should be around this unit during operation for air flow Reducing this clearance will reduce air flow to the machine causing operational temperatures to increase Possible damage to the machine can result if to much air flow is restricted OUT
70. e A 2 Type TABLE A 2 Common Electrical Devices ELECTRICAL DEVICE USE WITH THE OUTBACK 185 Possible Concerns Resistive Heaters toasters incandescent light bulbs electric range hot pan skillet coffee maker NONE Capacitive TV sets radios microwaves appliances with electrical control Voltage spikes or high voltage regulation can cause the capac itative elements to fail Surge protection transient protection and additional loading is recom mended for 100 fail safe opera tion DO NOT RUN THESE DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS Inductive Capacitive Inductive Single phase induction motors drills well pumps grinders small refrigerators weed and hedge trimmers Computers high resolution TV sets complicated electrical equipment These devices require large current inrush for starting See AUXILIARY POWER APPLICATIONS in the OPERA TION section of this manual for required starting wattages Some synchronous motors may be frequency sensitive to attain maximum output torque but they SHOULD BE SAFE from any frequency induced failures An inductive type line condition er along with transient and surge protection is required and liabilities still exist DO NOT USE THESE DEVICES WITH A OUTBACK 185 The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to a OUTBACK 185 OUTBACK
71. e Figure B 1 for the location of the following features Return to Master TOC Return to Section TOC eio f i c 5 5 amp c Return to Section TOC Return to Master TOC 1 CURRENT CONTROL DIAL Adjusts continuous cur rent output The amperages on the dial correspond to the approximate amperages needed for specific Lincoln welding electrodes 80 AMP CIRCUIT BREAKER Provide separate over load current protection for the 120 Volt and 240 Volt Receptacles WELD POSITIVE OUTPUT TERMINAL Provides the connection point for either the electrode holder or the work cable Because the 185 is a DC output machine either output terminal can be used for either cable WELD NEGATIVE OUTPUT TERMINAL Provides the connection point for either the electrode holder or the work cable Because the OUTBACK 185 is a DC out put machine either output terminal can be used for either cable GROUND STUD Provides a connection point for con necting the machine case to earth ground for the safest grounding procedure CIRCUIT BREAKER Provides overload protection for weld output terminals CIRCUIT BREAKERS 2 Provide separate overload cur rent protection for the 120 volt and 240 volt receptacles 240 VOLT RECEPTACLE Connection point for supply ing 250 volt power to operate one electrical device 120 VOLT DUPLEX REC
72. e fan 2 d 3 Do not place your body between the electrode and Do not attempt to override the governor or work cables If the electrode cable is on your right idler by pushing on the throttle control rods side the work cable should also be on your right side AR while the engine is running Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while d 5 Do not work next to welding power source turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate OUTBACK 185 LINCOLN B Return to Master TOC Return to Master TOC o 5 o gt 2 E tc Return to Master TOC 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 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting
73. e generator is now producing normal AC power from all four of the windings These windings consist of two 64 VAC weld windings a 120 240 VAC auxiliary power winding and an 82 VAC excitation winding NOTE Unshaded areas of Block Logic Diagram are the subject of discussion OUTBACK 185 LINCOLN B ES THEORY OF OPERATION T FIGURE E 6 GENERATING POWER o e i o a 9 D D Pd HE ou Ee gt LEVEL Ha MODULE EAE 9 KOHLER REACTOR s L E AUXIIARY WINDINGS FA alz RINGS amp nn Y Y output KE IGNITION ENGINE obs 3 WINDINGS AA H FLASE STUDS BRUSHES mmm SD D ALTERNATOR SOLENOID PAPAS 5 BAS rod ojo OIO BATTERY ENGINE x clo SHUTDOWN oleo RELAY OUTPUT 1 Il r 212 rh ns 212 METER FIELD CONTROL PC BOARD GENERATING POWER continued DC Weld Output Weld Boost AC output from the two phase shifted weld windings Outback 185 is equipped with a weld boost cir pass through a reactor then to a two phase brid
74. elines detailed throughout this manual OUTBACK 185 LINCOLN 5 os OPERATION Bod GRAPHIC SYMBOLS USED ON THIS EQUIPMENT OR IN THIS MANUAL WARNING CAUTION Return to Section TOC Return to Master TOC AIR CLEANER CIRCUIT BREAKER GROUND WORK CLAMP AUXILIARY POWER Return to Section TOC Return to Master TOC ELECTRODE WELDING ARC lt gt ENGINE OFF 7 AUTOIDLE A ENGINE START eio OJO gt 091 dc a 5 5 amp c Return to Section TOC Return to Master TOC OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio E f i a cre 5 5 amp c Return to Section 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 constant current for welding with DC stick electrodes A single dial lets you select a full range of welding output from 50 to 185 amps As a generator it can supply up to surge watts or con tinuous watts of 120 240 volt single phase AC power The machine is portable A Kohler CS 12 75 HP air cooled OHV gasoline engine powers the welder generator It has an engine warranty of 3 years RECOMMENDED APPLICATIONS Welder The 185 provides exc
75. ellent constant rent DC welding output for stick SMAW welding Generator The OUTBACK 185 gives smooth AC generator out put for continuous auxiliary power usage within the engine manufacturer s required maintenance recom mendations OPERATIONAL FEATURES AND CONTROLS The 185 was designed for simplicity Therefore it has very few operating controls A single dial on the control panel lets you select either welder or generator use For welding the same dial selects continuous current output over the machine s 50 to 185 amp range The gasoline engine controls include a recoil starter choke and stop switch See ENGINE OPERATION in the OPERATION section of this manual for details about starting running stopping and breaking in the gasoline engine B4 OPERATION B4 DESIGN FEATURES AND ADVANTAGES 185 amp DC constant current welding for stick electrodes Lightweight portable Full range continuous welding output control with a single knob Automatic shutdown under low oil level condition Hour Meter Standard Surge watts or Watts of continuous 120 240 volt single phase AC auxiliary power Kohler CS 12 75 HP overhead cam air cooled gasoline engine Smooth running long life WELDING CAPABILITY 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 pe
76. en end whichis the sealing area NEVER install a damaged filter A new Donaldson radial seal filter may have a dry lubricant on the seal to aid installation 5 Insert the New Radial Seal Filter Properly If you re servicing the safety filter this should be seated into position before installing the primary filter Insert the new filter carefully Seat the filter by hand making certain it is completely into the air cleaner housing before securing the cover in place The critical sealing area will stretch slightly adjust itself and distribute the sealing pressure evenly To complete a tight seal apply pressure by hand atthe outer rim of the filter not the flexible center Avoid pushing on the center of the urethane end cap No cover pressure is required to hold the seal NEVER use the service cover to push the filter into place Using the cover to push the filter in could cause damage to the housing cover fasteners and will void the warranty If the service cover hits the filter before it is fully in place remove the cover and push the filter by hand further into the air cleaner and try again The cover should go on with no extra force Once the filter is in place secure the service cover Caution NEVER use the service cover to push the filter into place Using the cover to push the filter in could cause damage to the housing cover fasteners and will void the warranty 6 Check Connectors for Tight Fi
77. equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applica tions 1 1 Portions of the preceding text are contained in EN 60974 10 Electromagnetic Compatibility EMC prod uct standard for arc welding equipment OUTBACK 185 LINCOLN B MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Accessories 01 a Section Maintenance Section D Theory of Operation eue due rw Or ee EUR 2 6 x ee eee Erw ui Section E Troubleshooting and Repair Section F Electrical Diagrams 22 dati xksa du d da data E RR ee Section G Parts Manual OUTBACK 185 LINCOLN 5 Return to Master TOC Return to Master TOC o 5 o gt 2 E tc Return to Master TOC iun TABLE OF CONTENTS INSTALLATION SECTION Pet Installation sunset a ia da nie S LI S Sc D A 1 Technical Specifications A 2 Safety Precautions sre agag saai pua i aea a REP A 3 Location and A 3 3 Stacking coxa Meee A
78. event hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting ch
79. g 4 Insert the electrode into the electrode holder 5 Set the current control dial to the desired output current 6 Start the gasoline engine See ENGINE OPERATION in this section of the manual 7 Strike an arc and begin welding AFTER YOU FINISH THE WELD 1 Stop the gasoline engine See ENGINE OPERA TION in this section of the manual 2 Allow the electrode and work to cool completely 3 Remove the work clamp from the work 4 Remove any remaining piece of electrode from the electrode holder 5 f you are finished using the OUTBACK 185 for welding disconnect the welding cables from the weld output terminals Reattach the flange nuts and leave them on the terminals For DC welding the electrode cable is to be connected to the output stud and work cable to the output stud For DC welding reverse these connections Semi automatic Wire Welding with a Lincoln Wire Feeder Welder The 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 equipped with the essentials needed for Gas Metal Arc Welding GMAW or MIG processes while others require the purchase of a conversion kit These products are available where Lincoln products are sold Contact your local authorized Lincoln represent
80. ge rec cuit that improves weld performance The reactor con EE tifier DC output from the rectifier is then stabilized by a weld boost winding that produces output rela 515 choke and terminates at two weld output terminals tive to the weld current In high welding load situations E 8 the exciter winding will tend to drop off in output while Weld Output Control the boost winding s output tends to increase The out Weld output is controlled by varying the current in the put from this boost winding is routed through a circuit 5 rotating field winding This is done through circuitry on breaker It is then rectified and added to the exciter cir 5 5 the PC board that detects the position of the output resulting in a significant improvement weld per c control potentiometer and then limits the rotor current formance accordingly NOTE Because the strength of the rotating field affects the output of all the windings auxiliary output will also drop when the weld output control setting is decreased NOTE Unshaded areas of Block Logic Diagram are the subject of discussion OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC F1 TABLE OF CONTENTS TROUBLESHOOTING AND REPAIR F1 o Troubleshooting and Repair F 1 gt 2 5 How to Use Troubleshooting Guide
81. he negative connection to the solenoid is restored and the engine will drop to low idle RPM NOTE Unshaded areas of Block Logic Diagram are the subject of discussion OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC eio OJO f gt a 5 5 amp c Return to Section TOC Return to Master TOC THEORY OF OPERATION ENS FIGURE E 5 GENERATING POWER OIO CURRENT 120 VAC RECEPTACLES SENSOR 240 VAC RECEPTACLE c 2 o 2 D OIL LEVEL I OIL INDICATOR d a o LEVEL E o MODULE Eales olo KOHLER REACTOR OIL LEVEL AUXIIARY WINDINGS SWITCH eee 8 sur STATOR TA e olo RINGS o a yo web Qe OUTPUT OUTPUT IGNITION ENGINE ROTOR WINDINGS RECTIFIER fX 2 PHASE STUDS BRUSHES ARRA STARTER mE EXCITER 1 SOLENOID ALTERNATOR SOLENOID WINDING PPT wy BOOST 2 WINDING ENGINE gt SHUTDOWN RELAY OUTPUT AUTOMATIC OUTPUT CONTROL IDLER CONTROL CIRCUIT A t CIRCUIT rh rh
82. ibility 2004 108 EC It was manufactured in conformity with a national standard that implements a harmonized standard EN 60974 10 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic screen enclosing the power sour
83. ician in checking for faults in the rotor winding MATERIALS NEEDED Analog Ohmmeter OUTBACK 185 LINCOLN B F 31 552 TROUBLESHOOTING AND REPAIR po ROTOR RESISTANCE AND GROUND TEST DYNAMIC continued FIGURE F 11 BRUSH AND SLIP RING LOCATIONS Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i a 5 5 gt Return to Section TOC Return to Master TOC Return to Master TOC SLIP RINGS BRUSHES KK 7 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 the brushes and slip rings are clean in good condition and are properly seated 2 Perform the Brush and Slip Ring Service reinstall the brush holder and brush assembly 3 Insulate the lead wires that had been discon nected from the brushes during the static rotor resistance test 4 Securely attach the ohmmeter leads to the brush terminals Use clips or terminals to attach the leads BEFORE starting the engine See Figure F 11 kG Start the engine and run it at high idle speed The resistance should read approximately 9 ohms at 77 F 25 C Shut off engine and move one of the ohmmeter leads to a good clean chassis
84. ion Manual for fur ther details CAUTION IN ORDER ACCOMPLISH THIS BREAK IN THE UNIT SHOULD BE SUBJECTED TO MODERATE LOADS WITHIN THE RATING OF THE MACHINE AVOID LONG IDLE RUNNING PERIODS REMOVE LOADS AND ALLOW ENGINE TO COOL SEVERAL MINUTES AT LOW IDLE BEFORE SHUTDOWN Low Oil Sensing This engine has a built in sensor which responds to low oil level not pressure When activated the system will shut the engine down The engine will not restart until sufficient oil is added Check oil level frequently and add oil as required to the full mark on the dipstick DO NOT OVERFILL Typical Fuel Consumption KOHLER CS 12 75 HP NO LOAD 2250 R P M 20 GALLONS HOUR 75 LITERS HOUR NO LOAD 3750 R P M 40 GALLONS HOUR 1 51 LITERS HOUR DC CC WELD OUTPUT 100 AMPS 25 VOLTS 73 GALLONS HOUR 2 77 LITERS HOUR AUXILIARY POWER 5200 KVA OUTBACK 185 LINCOLN 5 99 GALLONS HOUR 8 74 LITERS HOUR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC c 42 2 tc Return to Section TOC Return to Master TOC 5 o gt 2 E r E OPERATION E WELDING OPERATION WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet cloth ing Insulate yourself from work and ground Always wear dry insulating gloves
85. ion system by opening a ground lead from the engine magneto When the switch is held in the Start position the starter motor solenoid is activated cranking the engine After the engine starts the switch is released and returns to the high idle position the battery is removed or completely dead the engine will not start ENGINE PROTECTION The Kohler engine has a built in oil level sensor that is connected to an oil level module If the oil level is low the ignition magneto is disabled This will prevent the engine from starting or shut it down Low oil level will also cause a warning light on the Outback s control panel to flicker for a few seconds when cranking the engine NOTE Unshaded areas of Block Logic Diagram are the subject of discussion OUTBACK 185 LINCOLN B E THEORY OF OPERATION FIGURE E 3 ENGINE STARTING PROTECTION AND BATTERY CHARGING e CURRENT 120 VAC RECEPTACLES 240 SENSOR RECEPTACLE D D D D 3 zp 5 2 m D OIL LEVEL I Ole OIL INDICATOR isa lero gt LEVEL il 1 ao MODULE 582 9 KOHLER
86. ions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the adjustment of the throttle MATERIALS NEEDED Flathead Screw OUTBACK 185 LINCOLN B F 17 Return to Section TOC Return to Master TOC Return to Section TOC eio E f i Q amp a 21e 5 5 gt amp Return to Section TOC Return to Master TOC Return to Master TOC oe TROUBLESHOOTING AND REPAIR cae THROTTLE ADJUSTMENT PROCEDURE continued FIGURE F 4 HIGH AND LOW IDLE ADJUSTMENT HIGH IDLE ADJUSTMENT LOW IDLE ADJUSTMENT TOP VIEW OF ENGINE PROCEDURE High Idle Adjustment Low Idle Adjustment 1 With engine running and no load applied to the machine place the engine switch in the AUTO IDLE position Wait for the idle solenoid to energize and the engine speed to drop and sta bilize at low idle RPM 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 the HIGH IDLE position The solenoid should load on the machine If the high idle RPM requires adjustment using
87. ires connecting the fuse switch and starter solenoid See the wiring diagram Check for battery voltage at the PC board pin J3 10 lead 211 If voltage is not resent the engine switch or wire 211 may be defective Check PC board ground at pin J1 2 lead GND G Place the engine switch in the stop position unplug engine to welder harness connector 4 4 located inside the control box at the bottom left CAUTION Disconnecting this plug disables the normal engine shut down function of the engine switch CAUTION 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 OUTBACK 185 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e c Return to Section Return to Master TOC o 5 o E 2 E tc 5 TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S Continued The engine will not shut down OUTPUT PROBLEMS 8 Observe the oil level indicator light while cranking the engine If the light is blinking while cranking the engine the oil level may be low or the oil level
88. is likely defective 1 Perform the Engine RPM adjustment procedure The brushes and slip rings may be worn or faulty Perform the brush and slip ring service procedure Perform the battery and charging system tests 4 Perform voltage tests 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 OUTBACK 185 LINCOLN t TROUBLESHOOTING AND REPAIR is Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The welding arc is cold or weld 1 The weld boost circuit breaker 1 Perform the Engine performance is poor Engine may have tripped This circuit adjustment procedure operates normally and auxiliary breaker is a small button on the output is normal bottom of the control box not 2 The brushes and slip rings far from the positive weld output may be worn or faulty Perform terminal the brush and slip ring service procedure Check the weld cables electrode holder and work 9 Perform the battery and clamp Try welding with a charging system tests known good set of short 4 Perform the eld boost adequately sized cables The battery
89. istance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if there are undesirable electrical connections between the stator windings and chassis ground or between individual windings within the stator This test should be performed if flashing voltage is present at the rotor slip rings but the voltage output on leads 7 and 9 is too low MATERIALS NEEDED Miscellaneous hand tools Ohmmeter OUTBACK 185 LINCOLN B F 33 STATOR SHORT CIRCUIT AND GROUND TEST Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e 69 Return to Section Return to Master TOC o 5 o E 2 E r F 34 TROUBLESHOOTING AND REPAIR 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 See wiring diagram 4 Disconnect and isolate lead 5 from the neutral stud on the control panel bottom See wiring diagram 5 Disconnect the 7 and 9 leads from the PC board 6 Using an ohmmeter check the resistance between chassis ground and each of the fol lowing points resistance should read very high 500 000 500k ohms minimum a The 5 lead that h
90. kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 i SAFETY ARC RAYS can burn 4 a Use shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards 4
91. lication B 9 o 5 o gt 2 E t Return to Master TOC OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i Oo amp a gt 5 5 amp Return to Section TOC Return to Master TOC Return to Master TOC 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 Do Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn 24 eM Wear eye ear and body protection ui OPERATION WARNING ENGINE EXHAUST can kill 2 Use in open well ventilated areas or vent exhaust outside Do not stack anything on or near the engine MOVING PARTS can injure Do not operate with doors open or guards off WV Stop engine before servicing Keep away from moving parts Only qualified personnel should install use or service this equipment Observe additional Safety Guid
92. lity tion and wait for the idle solenoid to energize ole digital multimeters also have this function The engine RPM should drop and stabilize at and can be easily utilized See the the low idle RPM 5 facturer s instructions for your frequency 5 The frequency should read between 47 5 and or counter or multimeter 41 6 Hz 1 Set your frequency counter per the meter man 6 nage ra If either of the readings is incorrect proceed to ufacturer s instructions and plug it into one of the Throttle Adjustment Procedure later in the 120VAC auxiliary receptacles this Section 2 Start the engine and place the idle switch in the HIGH IDLE position Make sure that there is 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 2 3600 RPM 3 The frequency should read between 61 6 and 63 3 Hz Return to Section TOC Return to Master TOC OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio E f i 2 amp a 21e 5 5 amp Return to Section TOC Return to Master TOC Return to Master TOC itii TROUBLESHOOTING AND REPAIR ds ENGINE RPM ADJUSTMENT PROCEDURE continued FIGURE F 3 VIBRATACH METHOD HIGH IDLE ADJUSTMENT LOW IDLE ADJUSTMENT TOP VIEW OF ENGINE Vibratach Method A Vibra
93. m Remove the plastic brush cover from the end of the generator See Brush and Slip Ring Service Procedure Attach voltmeter leads to the brush terminals The positive terminal is closest to the genera tor winding Start the engine and place the engine switch in the HIGH position 7 The voltmeter should read about 50 VDC 8 If the voltage reading is zero or near zero per form the Rotor Resistance Test 9 Check for battery voltage at lead 224 J1 9 Check that the PC board is properly grounded at lead GND G J1 2 If the board is getting battery voltage and is properly grounded replace the board 10 If the voltage reading is about 3 to 5 volts DC check for AC voltage between Lead 7 Terminal B2 and Lead 79 Terminal B1 If the voltage is about the same or higher than the voltage reading of the brush leads replace the board 11 If the AC voltage between leads 7 and 9 is significantly lower than the DC voltage on the brush leads perform the Stator Short Circuit and Ground Test and Stator Voltage Test OUTBACK 185 LINCOLN B F 24 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i c a 5 5 amp c Return to Section TOC Return to Master TOC F 25 TROUBLESHOOTING AND REPAIR 8 BATTERY CHARGING SYSTEM TEST WARNING Service and repair should be
94. 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 It can operate at an angle but this should never be more than 15 degrees in any direction If you do operate it at a slight angle be sure to check the oil regularly and keep the oil level full Also fuel capacity will be a little less at an angle LIFTING The OUTBACK 185 should be lifted by two people See Technical Specification page for weight The LowLift grab bars on both ends make lifting easi er PRE OPERATION ENGINE SERVICE Read and understand the engine operating and maintenance instructions supplied with this machine before you operate the OUTBACK 185 WARNING Keep hands away from muffler or HOT engine parts Stop the engine when fueling Do not smoke when fueling Remove fuel cap slowly to release pressure Do not overfill tank Wipe up spilled fuel and allow fumes to clear before starting engine Keep sparks and flame away from tank OIL The OUTBACK 185 is shipped with the engine filled with SAE 10W30 CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE This is an added precaution Do not screw in dipstick when checking oil level DO NOT OVERFILL Be sure the fill
95. n TOC Return to Master TOC 1 79018 MONO_IN OSC_INH 8 55 DECODE OVERCURRENT CLOCK INH PROTECTION 224 42 BATTERY 2901N 0125 RN Return to Master TOC Return to Section TOC 160V 0 0018F POT INPUT CURRENT T Ca C20 7 8 A 13 50V E lt CONTROL eio OJO f i c a 5 5 amp c OVERCURRENT PROTECTION CLUSTER 1
96. nce should be very high at least 500 000 500k ohms 7 If the test does not meet the resistance specifi cations then the rotor may be faulty and should be replaced 8 If this test meets resistance specifications con tinue testing using the Dynamic Rotor Resistance and Ground Test Voltage shown is for a stator that is at normal full load temperature Readings will likely be slightly higher if machine is cold OUTBACK 185 LINCOLN 5 F 30 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i c a 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 31 TROUBLESHOOTING AND REPAIR 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will aid the techn
97. nd bracket It is also highly recommended that the bearing be replaced 2 Examine the cast end brackets and the stator assembly Be sure the locating points are free of varnish and any debris 3 Place the stator in the cast end bracket 4 Clean the bearing recess in the brush end bracket and install a new tolerance ring 5 Place the brush end bracket over the stator Use a plastic or rubber hammer to tap the bracket in place RUBBER ENGINE MOUNT OTHER ENGINE MOUNTS NOT VISIBLE FROM THIS ANGLE LA Adjust the stator and brackets as needed and install the stator through bolts placing the hard ware components the same as they were before removal Place the engine and generator assembly into the tubular frame of the machine and loosely install the rubber mount fasteners Make final adjustments to the position of the brackets and stator The stator lead bundle should exit the end bracket at the center of the hole provided Evenly tighten the stator through bolts to a torque of 4 5 to 5 5 ft Ibs Tighten the mounting fasteners OUTBACK 185 LINCOLN B ren TROUBLESHOOTING AND REPAIR 5750 STATOR REMOVAL REPLACEMENT PROCEDURE continued FIGURE F 20 STATOR LOCATION Return to Section TOC Return to Master TOC TOLERANCE RING STATOR Return to Section TOC Return to Master TOC 10 Check the air gap between the rotor and the stator Feeler gages are inserted between the r
98. nd on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre pers
99. neral 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 e is provided on the front of the welder WARNING DO NOT GROUND MACHINE TO A PIPE WHICH CAR RIES EXPLOSIVE OR COMBUSTIBLE MATERIAL OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 091 Of c a 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC INSTALLATION ax 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 All electrical equipment must be in safe operating condition AUXILIARY POWER RECEPTACLES The control panel of the 185 features three auxiliary power receptacles Two 20 amp 120 volt duplex double outlet
100. ng Symptoms are grouped into the following categories output problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION The last column labeled Recommended Course of Action lists the most likely com ponents that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the specified test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Contents to locate the appropriate diagram CAUTION 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 t
101. ns and parts lists Hazards of Electric Shock Exhaust amp Moving Parts WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet cloth ing Insulate yourself from work and ground Engine Jl Always wear dry insulating gloves ENGINE EXHAUST can kill 2 Use in open ventilated areas or vent exhaust outside Do not stack anything on or near the engine MOVING PARTS can injure Do not operate with doors open guards off A Stop engine before servicing Keep away from moving parts Only qualified personnel should install use or service this equipment LOCATION AND VENTILATION Whenever you use the OUTBACK 185 be sure that clean cooling air can flow around the machine s gasoline engine and the generator Avoid dusty dirty areas Also keep the machine away from heat sources Do not place the back end of the generator anywhere near hot engine exhaust from another machine And of course make sure that engine exhaust is ventilated to an open outside area The OUTBACK 185 must be used outdoors Do not set the machine in puddles or otherwise submerge it in water Such practices pose safety hazards and cause improper operation and corrosion of parts Always operate the OUTBACK 185 with the case roof on and all machine components completely assembled This will help to protect you from the dangers of moving parts
102. o E 2 E tc vf TROUBLESHOOTING AND REPAIR d Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Engine will not idle down Weld 1 Check that the engine switch is 1 The idle solenoid may be and auxiliary outputs are normal in the Auto position improperly adjusted Perform 2 Check that th ine choke i the Engine RPM adjustment fully open 2 With the engine running place the engine switch in the Auto position Check for battery voltage at the idle solenoid lead 213B if battery voltage is not present check engine switch connector P4 J4 and leads 213A and 213B 3 There may be a load on the weld or auxiliary output Disconnect all cables and cords If battery voltage was detected in step 72 above check connector P4 J4 leads 215 and 215A Check for AC voltage at leads 260 J2 3 and 261 J2 4 With no load on either the weld or auxiliary output the meter should read about 26 mV the voltage is significantly higher than this the toroidal current transformer may be faulty or improperly wired This may also indicate a load on machine input or faulty internal components drawing current the above readings are normal replace the PC board Engine idles own but will not stay Low idle ROM may be set too low at low idle Perform the adjustment procedure
103. o the State of California to cause cancer birth defects or other reproductive harm The Above For Diesel Engines Ihe Above For Gasoline Engines ARC WELDING can be hazardous PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 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 FOR ENGINE 1 h To avoid scalding do not remove the e radiator pressure cap when the engine is powered equipment Wa hot 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 1 ELECTRIC AND 2m MAGNETIC FIELDS 1 c Do not add the fuel near an open flame weld dangerous ing arc or when the engine is running Stop the engine and all
104. onnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier i SAFETY iv 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques
105. ontinued FIGURE F 15 BATTERY LOCATION MOUNTING BRACKET BATTERY OUTBACK 185 LINCOLN B F 41 F 42 NOTES OUTBACK 185 LINCOLN F 42 DOL 19159 01 DOL J8ISEN 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 Fs TROUBLESHOOTING AND REPAIR pu CONTROL BOX 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the control box MATERIALS NEEDED Cable Ties Wire Marking Supplies Wiring Diagram Phillips Screwdriver 3 8 Wrench 7 16 Wrench Needle Nose Pliers Return to Section TOC Return to Master TOC eio OJO f i
106. operly connected adequately charged Try cranking the engine using the recoil starter If the engine will still not turn or the recoil starter is hard to pull remove the spark plug and check for water or oil in the cylinder Also check for high oil level If the engine cranks normally while using the recoil starter remove the top cover from the machine ad check the fuse The fuse is located under the white cover of the back of the control box Engine will not start The starter 1 using the recoil starter be motor will crank the engine sure the engine switch is in the normally high or auto position Check that the fuel valve is open and that there is sufficient fresh gasoline in the tank Be certain that the battery is properly connected adequately charged even if using the recoil starter Check the engine oil level Check or replace the fuel filter Check or replace air filter Check the spark plug Clean or replace if necessary F 4 1 Test the fuse located under the white cover at the back of the control box Test for battery voltage at lead 210B where it connects to the starter solenoid while holding the switch in the start position If voltage is present the starter solenoid assembly is defective contact the engine manufacturer for parts and service If battery voltage is not present check the engine switch and all connectors and w
107. otor 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 gage 11 Reinstall the control box and fuel tank previ ously removed eio OJO f i Q a 21e 5 5 gt amp 12 Replace the case wraparound cover Return to Section TOC Return to Master TOC OUTBACK 185 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i c a 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 51 TROUBLESHOOTING AND REPAIR F 51 ROTOR 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877
108. ow it to cool before refuel 2 a Electric current flowing through any conductor causes ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in posi before welding tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts Exposure to EMF fields in welding may have other health when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to IN EME CASOS Ie quay Ds minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove p 9 guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 1 Route the electrode and work cables together Secure Always use the greatest care when working near moving them with tape when possible parts 2 4 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engin
109. 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the battery charging system is functioning properly MATERIALS NEEDED Misc hand tools Multimeter Jumper lead with a 10 amp inline fuse or circuit breaker OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i c 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 26 TROUBLESHOOTING AND REPAIR BATTERY CHARGING SYSTEM TEST continued FIGURE 8 CHARGING SYSTEM BATTERY PROCEDURE WARNING DO NOT REMOVE BATTERY CABLE WHILE MACHINE IS RUN 4 NING OR ATTEMPT TO OPERATE 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 securel
110. prevent the engine from accidentally starting dis connect the spark plug lead before servicing the engine See the Kohler Owner s manual for a summary of maintenance intervals for the engine Follow either the hourly or the calendar intervals whichever come first More frequent service may be required depending on your specific application and operating conditions The Kohler Owner s manual shows engine maintenance replacement parts and numbers OIL Check the oil level after every 5 hours of operation or daily SURE TO MAINTAIN THE OIL LEVEL Change the oil the first time after 20 hours of opera tion Then under normal operating conditions change the oil after every 100 hours or once a year whichev er occurs first If the engine is operated under heavy load or in high ambient temperatures change the oil every 50 hours Drain the oil from the drain plug located on either side of the engine bottom as shown in Figure D 1 Refill through the oil fill plug until the oil reaches the full mark on the dip stick See Engine Owner s manual for spe cific oil recommendations FIGURE D 1 OIL DRAIN AND REFILL LOCATION Do not screw in dipstick to check oil FILL to FULL mark on dipstick recheck OIL DRAIN PLUG Oil drain Tighten dipstick firmly before starting FUEL At the end of each day s use refill the fuel tank to minimize moisture conden sation and dirt contamination in the fuel line
111. rained 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the stator MATERIALS NEEDED 1 2 Wrench 7 16 Wrench Hoist OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i Q a 212 CIE 5 5 gt amp c Return to Section TOC Return to Master TOC dns TROUBLESHOOTING AND REPAIR dinis STATOR REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 18 STATOR REMOVAL HAMMER TAPPING POINTS TOLERANCE RING BRUSH ASSEMBLY CAST END BRACKET BEARING BRACKET END COVER PROCEDURE 1 Perform the Control Box Removal Procedure 6 Using 7 16 wrench remove the four bolts connecting the cast stator brackets Note the 2 Hemove the brushes See the Brush and Slip precise position of all hardware components and washers Using a plas
112. riod The machine is capable of higher duty cycles at lower output currents For exam ple you can load the welder to 120 amps for ten min utes out of ten for a 10096 duty cycle The current is continuously variable from 50 to 185 amps DC The OUTBACK 185 can therefore weld with all 3 32 1 8 and most 5 32 diameter Lincoln DC electrodes LIMITATIONS The OUTBACK 185 is not recommended for any processes besides those that are normally per formed using stick welding SMAW procedures The OUTBACK 185 is not recommended for pipe thawing During welding generator power is limited to 100 watts and output voltages can drop from 120 to 80 volts and 240 to 160 volts Therefore DO NOT OPERATE ANY SENSITIVE ELECTRICAL EQUIP MENT WHILE YOU ARE WELDING OUTBACK 185 LINCOLN 5 B 5 B 5 OPERATION CONTROLS AND SETTINGS welder generator controls are located on the Output Control Panel Gasoline engine controls are mounted on the engine See Figure B 1 and the figures in engine operation section OUTPUT PANEL CONTROLS 9 2 11 Return to Section TOC Return to Master TOC gt 3 or4 FIGURE B 1 WELDER GENERATOR CONTROLS _ 10 HOUR METER Records the time that the engine has run for maintenance purposes Se
113. roubleshooting assistance before you proceed Call 1 888 935 3877 OUTBACK 185 LINCOLN B F 2 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC c 42 Return to Section TOC Return to Master TOC o 5 o 2 E tc TROUBLESHOOTING AND REPAIR Fs PC BOARD TROUBLESHOOTING PROCEDURES WARNING K e ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To 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 PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 Ifthe problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag
114. safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the rotor winding is open shorted or grounded MATERIALS NEEDED Miscellaneous hand tools Ohmmeter analog type meter required for dynamic resistance test Wiring Diagram OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio f i gt 5 5 gt amp c Return to Section TOC Return to Master TOC Return to Master TOC F 30 TROUBLESHOOTING AND REPAIR ROTOR RESISTANCE AND GROUND TEST STATIC continued FIGURE F 10 ROTOR RESISTANCE BRUSHES i 4 PROCEDURE 1 2 Turn the engine off Remove the plastic cover from the end of the generator See Brush and Slip Ring Service Using needle nose pliers remove the leads from the brush terminals This will electrically isolate the rotor windings Remove the brush and brush holder assembly See Brush and Slip Ring Service Procedure Using the ohmmeter check the rotor winding resistance across the slip rings Normal resis tance is approximately 9 ohms at 77 F 25 C AU 6 Measure the resistance to ground Place one meter probe on either of the slip rings Place the other probe on any good unpainted chassis ground The resista
115. sories are available for 2 2 your OUTBACK 185 from your local Lincoln 9 lt Distributor o 3 Accessory K875 Includes the following c Twenty feet 6 1 meters of 46 AWG electrode cable with lug Fifteen feet 4 6 meters of 46 work cable with lugs Work Clamp Headshield with No 10 filter Insulated electrode holder and sample electrodes 150 amp capacity Undercarriage K2722 1 A two wheeled hand mov able undercarriage is available for field installation Rotor Removal Kit 820925 A service kit with thru bolt and impact bolt s for removing the generator rotor from tapered engine crank shaft Spark Arrestor Kit K2793 1 Attaches to muffler exhaust tube Virtually eliminates spark emissions Return to Section TOC Return to Master TOC Canvas Covers 2804 1 To protect the Outback 185 when not in use Made from attractive red canvas which is flame retardant mildew resistant and water repellent eio OJO f i Q amp a 21e 5 amp Return to Section TOC Return to Master TOC OUTBACK 185 LINCOLN 5 ACCESSORIES Return to Master TOC Return to Master TOC o 5 o gt 2 E t Return to Master TOC D 1 TABLE OF CONTENTS MAINTENANCE SECTION Maintenance vs sudo ad ia marine ini LI E Sc Sc e DUE D 1 S tvice Instrctions ripae eee cire
116. system may be faulty Contact the engine manufacturer Locate F 5 RECOMMENDED COURSE OF ACTION Reconnect 4 4 to shut the engine down Attempt to start the engine using the recoil starter if the engine starts check lead 7212 for faulty insulation If lead 212 is good replace the PC board If the engine fails to start have the engine and oil level system checked by a qualified engine service technician Place the engine switch in the stop position and check for battery voltage at the PC board J3 10 lead 211 If voltage is present the switch is defective and ground the brown white lead from the engine ignition magneto If the engine still will not shut down the engine ignition magneto may be defective Contact a qualified engine technician If the engine shuts down when the brown white lead 1 grounded check wiring and connections at leads 212 GND I GND J and the brown leads between connector J4 P4 and the engine ignition magneto If these leads and connections are good replace the PC board 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 OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC
117. t Make sure that all mounting bands clamps bolts and connections in the entire air cleaner system are tight Check for holes in piping and repair if needed Any leaks in your intake piping will send dust directly to the engine OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 0 Q a 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC ps MAINTENANCE SAFETY PRECAUTIONS WARNING e 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 If guards are missing from the machine get replace ments from a Lincoln Distributor See the EXPLOD ED VIEW AND PARTS LIST at the back of this man ual Read the Safety Precautions in the front of this manu al and in the Kohler Operating and Maintenance Instructions manual before working on the OUT BACK 185 Keep all equipment safety guards covers and devices in position and in good repair Keep your hands hair clothing and tools away from the recoil housing fans and all other moving parts when start ing operating or repairing this machine ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE CAUTION To
118. tach is used to measure the vibrations 4 Move the idle switch to the AUTO IDLE posi caused by the running engine It can be positioned tion and wait for the idle solenoid to energize anywhere where the engine vibration is reasonably and the engine RPM to drop and stabilize at the strong low idle RPM 1 Read and understand the manufacturer s 5 Position and adjust the Vibratach it should read instructions for the Vibratach between 2250 and 2500 RPM 2 Start the engine and place the idle switch in the 6 If either of the readings is incorrect proceed to HIGH IDLE position Make sure there is no the Throttle Adjustment Procedure later load on the machine this section 3 Position and adjust the Vibratach is should read between 3700 and 3800 RPM OUTBACK 185 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i c a 5 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 17 TROUBLESHOOTING AND REPAIR 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 precaut
119. the gray one has a dip stick on it Bolt in casting is drain plug Spark plugs are resistor type Battery or Pull start Pull is done from the left rear side engine Engine is a Kohler CS12 75 aluminum block w case iron sleeve 12 75HP 3600RPM Air Cooler 1 cylinder Manual choke Front on left name plate Fuel consumption charts in IM manual to starter motor 12 SEC 4 Board Schematic 64793 back wall of control box THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL INC AND MAY NOT BE DUPLICATED COMMUNICATED PROPRIETARY amp TIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC peces rorem SCRE EQUIPMENT TYPE OUTBACK 185 PAGE 1 or 1 a ema mun NONE ECT MACHINE SCHEMATIC lt ON ALL ANGLES IS 5 OF A DEGREE A1 SIZE 86205 WITH PUBLISHED STANDARD MATERIAL SCALE THIS DRAWING INCH pare 38209 user CRMA0758 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual OUTBACK 185 a ELECTRICAL DIAGRAMS SCHEMATIC FIELD CONTROL IDLE PC BOARD G4793 1 SOLENOID 215 TO IDLE SOLENOID Return to Sectio
120. tic hammer gently 3 Label and disconnect any wiring connecting the and evenly tap outward on the end cast brack engine generator assembly to the tubular et See Figure F 18 frame Remove cable ties and flexible plastic The stator frame assembly now be carefully conduit as needed See wiring diagram removed 4 Using the 1 2 wrench remove the nuts secur IMPORTANT Handle and store the stator careful ing the generator and engine to the rubber ly to avoid damage to the windings mounts Note ground lead and washer place ment for reassembly See Figure 19 5 Use a hoist or get a helper and lift the engine and generator assembly out of the tubular steel frame Place the engine and generator assem bly on a strong solid work surface OUTBACK 185 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i Oo amp a 21e 5 5 gt amp Return to Section TOC Return to Master TOC F 49 TROUBLESHOOTING AND REPAIR p STATOR REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 19 NUTS amp 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 e
121. ublication 1 Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http Awww lincolnelectric com safety for additional safety information OUTBACK 185 LINCOLN 5 Return to Master TOC Return to Master TOC o 5 o gt 2 E tc Return to Master TOC PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse qua
122. ulb 100 Reciprocating Saw 900 Radial Arm Saw 2 600 olg Radio 50 pe Refrigerator Freezer small 600 1 500 2 400 2 Slow Cooker 200 o Submersible Pump 1 HP 1 000 2 500 4 000 de Sump Pump 600 1 500 2 400 513 Toaster 1 100 dc Weed Trimmer 500 Lincoln Wire Feeder Welder 4 000 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 Multiple loads can be used as long as the total load does not exceed 5 700 Peak watts Be sure to start the largest loads first OJO 091 a cre 5 5 amp OUTBACK 185 LINCOLN B B 10 NOTES OUTBACK 185 LINCOLN B 10 DOL 19159 01 DOL J8ISEN 01 DOL DOL 19139 uunjeH DOL uonoeg DOL 5 DOL 5 DOL 5 E TABLE OF CONTENTS ACCESSORIES SECTION E AGCCeSSOLIGS 2 ue I Deuce Gee Ree E oo Sid C 1 Options ACCESSONES eee tira be de pee ae Peor Rus C 2 Return to Master TOC Return to Master TOC o 5 o gt 2 E t Return to Master TOC OUTBACK 185 LINCOLN B OPTIONS ACCESSORIES E The following options acces
123. ur safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the case sheet metal covers MATERIALS NEEDED 3 8 Wrench Return to Section TOC Return to Master TOC eio OJO E f i 091 c 5 5 amp c Return to Section TOC Return to Master TOC OUTBACK 185 LINCOLN B diis TROUBLESHOOTING AND REPAIR 558 CASE COVER REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 13 CASE COVER REMOVAL CASE SCREWS Return to Section TOC Return to Master TOC CASE SCREWS Return to Section TOC Return to Master TOC 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 eio OJO f i Q a 21e 5 5 gt amp 3 To replace the cover reverse the above proce dure Return to Section TOC Return to Master TOC OUTBACK 185 LINCOLN 5 Return to Section TOC Return to Master
124. ut against the housing If your air cleaner has a safety filter replace it every third primary filter change Remove the safety filter as you would the primary filter Make sure you cover the air cleaner outlet tube to avoid any unfiltered contaminant dropping into the engine Clean Both Surfaces of the Outlet Tube and Check the Vacuator Valve Use a clean cloth to wipe the filter sealing surface and the inside of the outlet tube Contaminant on the sealing surface could hinder an effective seal and cause leakage Make sure that all contaminant is removed before the new filter is inserted Dirt accidently transferred to the inside of the outlet tube will reach the engine and cause wear Engine manufacturers say that it takes only a few grams of dirt to dust an engine Be careful not to damage the sealing area on the tube Wipe both sides of the outlet tube clean Outer edge of the outlet tube Inner edge of the outlet tube If your air cleaner is equipped with a Vacuator Valve Visually check and physically squeeze to make sure the valve is flexible and not inverted damaged or plugged Inspect the Old Filter for Leak Clues Visually inspect old filter for any signs of leaks A streak of dust on the clean side of the filter is a telltale sign Remove any cause of leaks before installing new filter 4 Inspect the New Filter for Damage Inspect the new filter carefully paying attention to the inside of the op
125. y connected 2 Start the engine and test the voltage at the bat tery terminals The meter should read between 13 5 and 14 5 volts DC 3 If the voltage is low shut off the engine 4 Disconnect lead 208 from the engine alterna tor and place a fused jumper lead between the alternator and the positive battery terminal See Figure F 8 See wiring diagram Start the engine and check voltage at the bat tery If the DC voltage is now 13 5 to 14 5 check leads 208 208A and lead 209 If these leads and connections are good replace the board If the voltage is still low or if the inline fuse blows the engine charging system is most like ly faulty Contact a qualified engine repair tech nician OUTBACK 185 LINCOLN B F 26 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i c a 5 5 amp c Return to Section TOC Return to Master TOC F 27 STATOR VOLTAGE TEST 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 If for any reason you do not understand the test pro

Lincoln Electric OUTBACK SVM204-A User's Manual

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