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Lincoln Electric IM972 User's Manual

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Contents

1. Gord WELDER GENERATOR CONTROLS See Figure B 1 for the location of the following features 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 30 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 OUTBACK 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 output 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 current protection for the 120 volt and 240 volt recepta cles 240 VOLT RECEPTACLE Connection point for sup plying 250 volt power to operate one electrical device 120 VOLT DUPLEX RECEPTACLES 2 Connection point for supplying 120 vo
2. SNOILO3HIQ 3150940 NI WOLLOS TANVd IOH1NOO NO 10 1 02 NO Qnis qaNnou9 Qnis TVH1n3N 8s 5 1909915 HO1VH3N39 luo 10 S 541 3LON 0100151 73431110 N3HM 035070 HOSN3S 18 91 5 yuvds GIoN3108 ualuvis 5100 ial GION310S vez lt GL Lo 4 H313N HOLVOICNI ONO INOW 73A31 98 MOVELNO INVH9VIG ELECTRIC OUTBACK 185 DIMENSION PRINT F 2 INVL 1905 ALdIN3 ANIONS HLIM ALIAVHO 40 H31N3O e ELECTRIC OUTBACK 185 5 OUTBACK 185 gro Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese it eS SIR Chinese Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate you
3. EE TROUBLESHOOTING E Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Major Physical or Electrical Damage is Evident No Generator power or welding output Generator power is available but unit will not weld Unit will weld but low or no generator power is available No auxillary power but machine has weld output OUTPUT PROBLEMS Contact your local Lincoln Authorized Field Service Facility Check brushes for wear See Maintenance section Check for loose or faulty connections at brush holders Open lead in flashing or field circuit Rheostat R1 lead broke Dirty slip rings Faulty rheostat R1 Faulty field bridge rectifier D1 Faulty field capacitor C1 Faulty stator field winding Faulty rotor If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility Loose connector to output stud Work not connected Electrode holder loose No open circuit voltage at output studs Open lead in weld circuit Faulty output bridge rectifier Faulty choke L1 Circuit breaker is open Loose or open connection with electrical plug in component Current control dial not at MAX No open circuit voltage at receptacle Check CB1 and CB2 Reset if tripped
4. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed OUTBACK 185 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION ENGINE PROBLEMS i i i 1 Engine Switch on HIGH Idle will not idle down to low 2 Engine choke is not fully open 3 Externalload on welder or auxiliary power Remove load 4 Machine output is under load or Engine switch in wrong position 5 Idle solenoid does not pull in Engine idles down to low idle but 1 Engine low idle RPM may be set will not stay at low idle too low Contact Lincoln Field Service Facility 1 Check Work and Electrode cables for loose or faulty con nections If all recommended possible areas 2 Mechanical linkage from sole of misadjustment have been noid to engine stuck checked and the problem persists 3 Open connection in weld circuit Contact your local Lincoln 4 No output from receptacles or Authorized Field Service Facility load too small 5 Idler pc board is not sensing output current 6 Faulty idler pc board Engine will not go to high idle when attempting to weld or use generator power Engine will not go to high idle when 4 Auxiliary load l
5. call Turn power off before servic ing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entretien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten N o opere com as tampas removidas 22 722 9 PERI 3378824 VY FE DF MTEL e HE i t ER AHS Aj sil uit e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les pan neaux ouverts ou avec les dis positifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes opere com os paineis e XJ p V IR 291 L Z 884 e TTD 985 MSR two Sel S 42 cils jlgall lia Jam ye Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO BIR Chinese LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR 588 0 8 018 EC AA TERUCTSU LTRHOREMELTR ET DO TE HE B BA
6. 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 Electric Skillet 1 250 Furnace Fan 1 3 HP 1 200 3 000 4 800 Portable Grinder 4 1 2 600 Portable Grinder 7 2 000 Halogen Work Light 500 Hand Drill 1 4 500 Hand Drill 3 8 700 1500 Watt Heater 1 750 Hedge Trimmer 450 Light Bulb 100 Reciprocating Saw 900 Radial Arm Saw 2 600 Radio 50 Refrigerator Freezer small 600 1 500 2 400 Slow Cooker 200 Submersible Pump 1 HP 1 000 2 500 4 000 Sump Pump 600 1 500 2 400 Toaster 1 100 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 OUTBACK 185 9 e ACCESSORIES OPTIONS ACCESSORIES The following options accessories are available for your OUTBACK 185 from your local Lincoln Distributor Accessory Kit K875 Includes the following Twenty feet 6 1 meters of 6 AWG electrode cable with lug Fifteen feet 4 6 meters of 6 work cable with lugs Work Clamp Headshield with N
7. 200 250 ft 61 76m OUTBACK 185 5 Cable Installation Install the welding cables to your OUTBACK 185 as follows See Figure A 1 for the location of parts 1 The gasoline engine must be OFF to install weld ing cables 2 Remove the 1 2 13 flanged nuts from the output terminals 3 Connect the electrode holder and work cables to the weld output terminals Normally the electrode cable is connected to the positive output stud 4 Tighten the flanged nuts securely 5 Be certain that the metal piece you are welding the work is securely connected to the work clamp and cable 6 Check and tighten the connections periodically CAUTION Loose connections will cause the output studs to overheat and the studs may eventually melt Do not cross welding cables at output stud connec tion Keep isolated and separate from one another Lincoln Electric offers a welding accessory kit with 6 welding cables See the ACCESSORIES section of this manual for more information For more information on welding see WELDING OPERATION in the OPERATION section of this man ual INSTALLATION A 5 MACHINE GROUNDING Because this portable engine driven welder or genera tor creates its own power it is not necessary to con nect 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
8. F 40 C TO 55 C OUTBACK 185 2 PRECAUTIONS Read this entire installation section before you start installation WARNING Do not attempt to use this equipment until you have thoroughly read all operating and mainte nance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists Hazards of Electric Shock Engine Exhaust amp Moving Parts A WARNING ELECTRIC SHOCK can kill not touch electrically live parts 3 or electrode with skin wet cloth ing Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill 3 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 Stop engine before servicing Keep away from moving parts Only qualified personnel should install use or service this equipment INSTALLATION A 2 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
9. 119 Zo Soares ASstHAlg2 dis de ule Lily vues ci yd pi Aeg READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO DENEINSATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de respiraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n Gardez la t te l cart des fum es 6 Utilisez un ventilateur ou un aspirateur pour les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Mantenha seu rosto da fumaca 9 59 844550 2 8 778 6 8 e FR E e FB sk e 24752 e 78 Ash 7154214 27 amp Qual oe Aul sul f J jaa yi 4i
10. Connect the work cable to the workpiece as close as possible to the area being welded 1 0 To prevent accidentally starting gasoline engines while 2 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 8 SAFETY ELECTRIC SHOCK can kill 3 8 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 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 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
11. 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 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 du corps PR CAUTIONS DE S RET POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER TRANSFORMATEUR a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel 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 8 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 mi
12. OFF switch on the Pro Cut OFF until the OUTBACK 185 has been started and is at full operating speed OUTBACK 185 9 7 224 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 A 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 electronic devices cannot be powered by the OUT BACK 185 Refer to Table A 2 ELECTRICAL DEVICE USE WITH THE OUTBACK 185 in the INSTALLA TION section of this manual GENERAL INFORMATION The OUTBACK 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
13. amps will need 240 watts of power 120 x 2 240 You can use Table B 3 AUXILIARY POWER APPLI CATIONS to determine the wattage requirements of the most common types of loads you can power with the OUTBACK 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 output 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 the largest loads first TABLE B 2 ELECTRODE SELECTION GUIDE CLASSIFICATION ELECTRODE TYPE ______ weEARSHELDeABR DC 50150 50 185 1 8 AND THINNER 1 8 AND THICKER SHEET THICKNESS CURRENT RANGE AMPS ELECTRODE 3 32 SIZE 1 8 SIZE 5 32 SIZE DC 5 50 75 75 135 90 175 80 145 105 135 145 180 125 185 OUTBACK 185 9 B 8 OPERATION B 8 TABLE B 3 AUXILIARY POWER APPLICATIONS Suggested Power Applications Running Watts Start up Watts 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
14. 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 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 Table B 2 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 2 3 Attach the work clamp securely to the work you are welding 4 Insert the electrode into the electrode holder 5 Setthe current control dial to the desired output current 6 Startthe 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 comp
15. gi A 3 Spark Attester 2 aee e re Ma S Fed a tente dede A 3 Electrical and Welding Connections A 4 Machine Grouriding di tr etr pnta er net er pan i ak amta Ge Susa A 5 Plugs and Hand Held Equipment Auxiliary Power Receptacles A 6 Premises WiN u LL ny det auqa 6 6 Electrical Devices used with the Outback 185 A 7 OGL Ath OM u usa Section B Salety 50 B 1 iile qe ne 2 EEUU B 3 Recommended Applications B 3 Operational Features and Controls u nennen 3 3 Capability 3 3 Controls 0 4 4 Engine 62 0 uc mH 5 Welding Operati us en rime tante en 6 me ERN B 7 Electrode selection Guide B 7 Auxiliary Power Application u uU e Pe ayasa tuer aded dare E ann B 8 ACCOSSOLFIGS Section C General Options Accessories C 1 M L Section D Safety Precautions ss sa u ne sd uda s aed h Edita kde
16. 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 1 ARC RAYS can burn 4 a Use a 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 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c 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 Welding may produce fumes and gases hazardous to health Avo
17. pl EZ t A SR M EL 36 SB 8 sy RD B 0 SIHAT FAP 555 ETMT BHC QU gl Jub al gly cael giall Gales ail World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
18. which this engine driven welder supplies power must a be grounded to the frame of the welder using a grounded type plug b double insulated When this welder is mounted on a truck or trailer the machine grounding stud must be securely con nected to the metal frame of the vehicle In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulat ed 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 provid ed on the front of the welder A WARNING DO NOT GROUND MACHINE TO A PIPE WHICH CARRIES EXPLOSIVE OR COMBUSTIBLE MATERIAL OUTBACK 185 6 INSTALLATION nm 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 insulated tool with a two blade plug A 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 OUTBACK 185 features three auxiliary
19. 00 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 1096 duty cycle on a ten minute basis This means that you can load the welder to 185 amps for one minute out of every ten minute period The machine is capable of higher duty cycles at lower output cur rents For example you can load the welder to 120 amps for ten minutes 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 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 EQUIPMENT WHILE YOU ARE WELDING OUTBACK 185 9 B 4 OPERATION CONTROLS AND SETTINGS welder generator controls are located on the Output Control Panel B 4 Gasoline engine controls are mounted on the engine See Figure B 1 and the figures in engine operation section OUTPUT PANEL CONTROLS
20. 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 e 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 IT 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 Instruction Manual for fur ther details CAUTION IN ORDER TO ACCOMPLISH THIS BREAK IN THE UNIT SHOULD BE SUBJECTED TO MODERATE LOADS WITHIN THE RATING O
21. F 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 sys tem will shut the engine down The engine will not restart until sufficient oil is added Check oil level fre quently 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 9 99 GALLONS HOUR 8 74 LITERS HOUR B 6 OPERATION p WELDING OPERATION A 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 Ae Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside Do not stack anything on or near the engine 3 MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing D Keep away from moving parts Only qualified personnel should install use or service this equipment The OUTBACK 185
22. 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 SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed OUTBACK 185
23. OCTOR 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 249 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 5 1 h To avoid scalding do remove the 1 e radiator pressure cap when the engine is powered equipment ANM Ww ve 1 8 Turn the engine off before troubleshooting and maintenance 2 work unless the maintenance work requires it to running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes 3 outdoors 5 X ELECTRIC AND SR MAGNETIC FIELDS 1 c Do not add the fuel near an open flame 350 may be dangerous welding arc or when the engine is running Stop the engine and allow it to cool before 2 a Electric current flowing through any conductor causes refueling to prevent spilled fuel from vaporiz localized Electric and Magnetic Fields EMF Welding ing on contact with hot engine parts and current creates EMF fields around welding cables and igniting Do not spill fuel when fillin
24. OUTBA CK TM 85 September 2010 For use with machines having Code Numbers 11516 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 OPERATOR S MANUAL 150 9001 55 gt 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 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The 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 D
25. The maximum A WARNING 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 Air Filter Element 63 083 19 S Air Filter Pre Cleaner 63 083 17 S Spark Plug Resistor Type Champion RC 12YC Gap 030 76mm 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 OUTBACK 185 ae E 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric
26. ar D 1 Routine and Periodic Engine D 1 D 2 Troubleshooting sens Section E How to Use Troubleshooting Guide E 1 Troubleshooting 2 4 Wiring Diagram and Dimension Print sens Section F Parts LISE uuu u P 591 Series vi 1 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 B400RPM 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 A 1 Capacities Fuel 6 86 gal 24 9L Oil 1 2 Qts 1 1L w Cast Iron Sleeve RATED OUTPUT WELDER 100 130 150 185 100 60 20 MAX OUTPUT OUTPUT WELDER AND GENERATOR Welding Ranges Welding Open Circuit Voltage AC Auxiliary Power 4600 Watts 115V 1PH 10096 Duty Cycle 5700 Peak Watts 5200 Continuous Watts 120 230 V 1PH 50 185 Amps DC 80 VDC Max PHYSICAL DIMENSIONS 25 47 in 21 12 in 31 48 in 310 0 Ibs 646 94 mm 536 45 mm 799 59 mm 140 6 kg OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 0 F 104 F 18 C TO 40 C 40 F 131
27. ations Refer to http www lincolnelectric com safety for additional safety information i SAFETY PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de 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 quand on soude dans des endroits humides ou sur un plancher metallique 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 defonctionnement 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 deu
28. cylinder and cylinder head fins and housing rotating screen and muffler areas 7 Storeinaclean dry area OUTBACK 185 ne INSTALLATION ns STACKING OUTBACK 185 machines CANNOT be stacked TILTING Place the machine on a secure level surface whenev er you use it or store it Any surfaces you place it on other than the ground must be firm non skid and structurally sound The gasoline engine is designed to run in a level posi tion for best performance 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 Specification section for weight The LowLift grab bars on both ends make lifting easier 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 w
29. 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 A 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 publication 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 8 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 recommend
30. does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registratio
31. ess than 100 watts using auxiliary power atts 2 Circuit breaker CB1 or CB2 tripped or faulty 3 Mechanical linkage from sole noid to engine stuck Engine runs erratic or stops running 1 Oil level may be low activating or engine surges at low idle the engine Oil Gard shutdown system Check oil level 2 Idle solenoid linkage or engine idle misadjusted Recoil starter is hard to pull 1 Crankcase may be over filled with oil Check oil level Water in engine from rain and or condensation Remove spark plug and dry it if wet Blow low pressure compressed air in spark plug port while pulling recoil starter Re install spark plug Spark plug may be faulty Air filter element saturated with water and or oil Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed OUTBACK 185 Engine will not start starts but runs rough with low power TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Engine runs erratically or stops running Engine sputters but will not start Recoil starter is hard to pull Arc is erratic and pops out Arc becomes Cold at the short Arc lenghts or shor
32. g tank If welding machines fuel is spilled 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 before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving 7 Exposure to EMF fields welding have other health parts when starting operating or repairing equipment effects which are now not known In some cases it may be necessary to remove safety All welders should use the following procedures in order to guards to perform required maintenance Remove minimize exposure to EMF fields from the welding circuit 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 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor 2 d 3 Do not place your body between the electrode and idler by pushing on the throttle control rods work cables If the electrode cable is on your right while the engine is running side the work cable should also be on your right side 2 4 4
33. haust outside Keep away from moving parts Do not operate with panels open or guards off MOVING OUTBACK 185 Erro INSTALLATION OUTBACK 185 OUTPUT CONNECTIONS FIGURE 1 CURRENT CONTROL DIAL WELD OUTPUT TERMINALS 2 GROUND STUD CIRCUIT BREAKERS 2 20 AMP CIRCUIT BREAKER 30 Amp RECEPTACLE 240 VOLT 50 AMP O1 B N ELECTRICAL OUTPUT CONNECTIONS See Figure A 1 for the location of the current control dial weld output terminals ground stud circuit break ers 240 and 120 volt receptacles WELDING CABLE CONNECTIONS Cable Size and Length Be sure to use welding cables that are large enough The correct size and length becomes especially impor tant when you are welding at a distance from the welder Table A 1 lists recommended cable sizes and lengths for rated current and duty cycle Length refers to the distance from the welder to the work and back to the welder Cable diameters are increased for long cable lengths to reduce voltage drops 7 DUPLEX RECEPTACLE 2 120 VOLT 20 AMP 8 HOURMETER 9 ENGINE SWITCH 10 CHOKE TABLE A 1 RECOMMENDED WELDING CABLE SIZE AND LENGTH TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable 125 Amps Length 30 Duty Cycle 0 50 ft 0 15m 6 AWG 50 100 ft 15 30 m 100 150 ft 30 46 m 150 200 ft 46 61 m
34. id 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 ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b 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 spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable PEL and ACGIH limits 5 c 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 5 d Shielding gases used for arc welding can displace air and cause injury or death Always use e
35. ion 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 chains crane cables or other alternate cir cuits 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 NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing 8 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators
36. ith SAE 10W30 oil 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 plug is tight after servicing FUEL m 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 approx imately 6 8 gallons 25 74 Liter DO NOT OVER FILL allow room in the fuel tank for fuel expansion SPARK ARRESTER Some federal state or local laws may require gaso line 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 Stop engine when fueling Do not smoke when fueling Keep sparks and flame away from tank Do not leave unattended while fueling Wipe up spilled fuel and allow fumes to clear before starting engine Do not overfill tank fuel expansion may cause overflow Close fuel shut off valve when transporting or not operating machine GASOLINE can cause fire or explosion ENGINE EXHAUST PARTS can kill can injure Use in open well ventilated area or vent ex
37. letely 3 Remove the work clamp from the work 4 Remove any remaining piece of electrode from the electrode holder 5 If you are finished using the OUTBACK 185 for weld ing disconnect the welding cables from the weld out put 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 OUTBACK 185 generator power can be used to supply up to 5 200 watts continuous input power to a Lincoln Wire Feeder Welder The Wire Feeder Welder is equipped with all the supplies needed for Flux Cored Arc Welding FCAW Also some Wire Feeder Welders come 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 representative for more details Plasma Cutting with Lincoln Pro Cut 25 The OUTBACK 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 following 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
38. lt power to operate devices needed for maintenance purposes 7 FIGURE B 1 10 HOUR METER Records the time that the engine 11 has run for maintenance purposes 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 5 position the engine starter motor is energized When in HIGH IDLE position the engine will run continuously at high idle When in AUTO IDLE lt IS 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 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 Ba ENGINE OPERATION Starting Shutdown Instructions
39. n Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS Page ALES EE LE LL OM SLT Section Technical Sp cifications A 1 Safety U u A 2 Location arid A 2 p 2 MIA E A 3 Liao A 3 3 1 Pre Operation Engine 56065 A 3 en E A 3
40. n 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 for specific oil recommendations ments from a Lincoln Distributor See the EXPLOD FIGURE D 1 OIL DRAIN AND ED VIEW AND PARTS LIST at the back of this 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 cov ers 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 starting operating or repairing this machine KXXX Do not screw in FILL to FULL mark on dipstick to check oil dipstick recheck ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE CAUTION To prevent the engine from accidentally starting dis connect the spark plug lead before servicing the engine Tighten dipstick Oil drain firmly before starting See the Kohler Owner s manual for a summary of maintenance intervals for the engine Follow either the FUEL At the end of each day s use refill hourly or the calendar intervals whichever come first the fuel tank to minimize moisture con More frequent service may be required depending on densation and dirt contamination in the your specific application and operating conditi
41. nough ventilation especially in confined areas to insure breathing air is safe 5 e Read and understand the manufacturer s instructions for this 5 f 8 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 SAFETY WELDING and CUTTING gt SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent 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 prevent 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 explos
42. o 10 filter Insulated electrode holder and sample electrodes 150 amp capacity Undercarriage K2722 1 A two wheeled hand movable undercarriage is available for field installa tion 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 Canvas Covers K2804 1 To protect the Outback 185 when not in use Made from attractive red canvas which is flame retardant mildew resistant and water repellent OUTBACK 185 o MAINTENANCE D 1 OIL Check the oil level after every 5 SAFETY PRECAUTIONS hours of operation or daily BE SURE TO MAINTAIN THE OIL LEVEL WARNING Change the oil the first time after 20 hours of opera tion Then under normal operating conditions Have qualified personnel do all maintenance and change the oil after every 100 hours or once a year troubleshooting work whichever occurs first If the engine is operated under heavy load or in high ambient temperatures Turn the engine off before working inside the change the oil every 50 hours machine 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 Remove guards only whe
43. ons The fuel line Kohler Owner s manual shows engine maintenance AIR CLEANER With normal operating replacement parts and numbers 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 ae 05 0 2 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 provided fiber spacer between the muffler and bottom of control panel See Figure D 2 FIGURE D 2 ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS
44. ouch electrically live parts 8 CR or vent exhaust outside or electrode with skin or wet Do not stack anything on or near clothing the engine Insulate yourself from work and ground k MOVING PARTS can injure Do not operate with doors open or Always wear dry insulating guards off gloves 4 Stop engine before servicing Keep away from moving parts FUMES AND GASES 23 can be dangerous Only qualified personnel should install use or service this equipment A Keep your head out of fumes Observe additional Safety Guidelines detailed Use ventilation or exhaust to throughout this manual 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 4 can burn Wear eye ear and body protection IN OUTBACK 185 GRAPHIC SYMBOLS USED ON THIS EQUIPMENT OR THIS MANUAL WARNING CAUTION AIR CLEANER CIRCUIT BREAKER GROUND WORK CLAMP AUXILIARY POWER ELECTRODE WELDING ARC ENGINE OFF AUTO IDLE ENGINE START OUTBACK 185 sas OPERATION ER 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
45. power receptacles Two 20 amp 120 volt duplex double outlet 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 sin gle phase 60 Hertz AC power The machine output voltages meet UL standards and fall within 1096 of the rated voltage PREMISES WIRING The OUTBACK 185 is not recommended for premises wiring The OUTBACK 185 does not have a combined 120 240 volt receptacle and cannot be connected to a premises as described in other Lincoln literature The OUTBACK 185 is intended only for backup intermittent use power Certain electrical devices can not be powered by the OUTBACK 185 Refer to Table 2 for these devices CIRCUIT BREAKERS m 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 WITHOUT OVERLOAD PROTECTION THE UNIT COULD OVERHEAT AND OR CAUSE DAMAGE TO THE EQUIPMENT BEING USED OUTBACK 185 INSTALLATION CAUTION Certain Electrical devices cannot be powered by the OUTBACK 185 See Table 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
46. 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 Single phase induction motors drills well pumps grinders small refrigerators weed and hedge trimmers These devices require large current inrush for starting See Table B 3 GENERATOR 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 Capacitive Inductive Computers high resolution TV sets complicated electrical equipment An inductive type line condition er along with transient and surge protection is required and liabilities still exist DO NOT USE THESE DEVICES WITH OUTBACK 185 The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to a OUTBACK 185 OUTBACK 185 zal OPERATION E SAFETY INSTRUCTIONS WARNING WARNING ES 221 ENGINE EXHAUST can kill 3 Use in open well ventilated areas Do not t
47. range of welding output from 50 to 185 amps As a generator it can supply up to 5700 surge watts or 5200 continuous 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 OUTBACK 185 provides excellent constant current DC welding output for stick SMAW welding Generator The OUTBACK 185 gives smooth AC generator output for continuous auxiliary power usage within the engine manufacturer s required maintenance recom mendations OPERATIONAL FEATURES AND CONTROLS The OUTBACK 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 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 5700 Surge watts or 52
48. rself from work No toque las partes los elec trodos bajo carga con la piel o ropa mojada Aislese del trabajo y de la tier ra Ne laissez ni la peau ni des v tements mouill s entrer en contact avec des pi ces sous ension Isolez vous du travail et la terre Ber hren Sie keine strom eile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem 4880208988 2188 6 6325 838 9 81 97 Z p grek 077 e aBOIERT AEB 3544 5898 Xe sn uc AU ne 2x2 HIE nile uil el jad oz ye alan 24 ON 3 il s Gall DUA tne Keep flammable materials away Mantenga el material com bustible fuera del rea de tra bajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem e R comitis 46105 48 e 1 59 5 66 848 AFI al gl ae e Wear eye ear and body tection Prot jase los ojos los o dos el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo B amp uv 3 e
49. se la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place V V for selecting a QUALITY product by Lincoln Electric We want you J hank OU to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor
50. 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 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 activi ties 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 You can 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 carbu retor 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
51. ts to the work piece WELDING PROBLEMS Engine is not fully warmed up and engine choke is in the fully open RUN position Engine requires service to head carburetor filters oil spark plug and or gas Oillevel to low Bad gas bad filter air cleaner spark plug and or breather Too much oil in crankcase Check Work and Electrode cables for loose or faulty connection Electrode may be wet Reset circuit breaker CB4 located under of the control panel the Current Control Dial on the bottom side If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed OUTBACK 185 DIAGRAMS E F 1 Jequunu epoo 1ueuudinbe jueureoe dai e 10 jueunredeq eu si eui J sourd einso oue y Jo euo uo pejsed si epoo je norued siu Ag seuluoeui 10 jou j 82821 Oom ren
52. x 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 soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier 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 lev age 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

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