RETURN TO MAIN MENU Operator’s Manual ™ OUTBACK 145 For use with machines having Code Numbers: 11732 Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Need Help? Call 1.888.935.3877 to talk to a Service Representative Hours of Operation: 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference Date Purchased After hours? Use “Ask the Experts” at lincolnelectric.
SAFETY PRODUCT MODEL THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELECTRIC. KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Material Safety Data Sheet (MSDS) and the warning label that appears on all containers of welding materials.
SAFETY PRODUCT MODEL 1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment. SECTION A: WARNINGS CALIFORNIA PROPOSITION 65 WARNINGS 1.e. In some cases it may be necessary to remove safety guards to perform required maintenance.
SAFETY PRODUCT MODEL ELECTRIC SHOCK CAN KILL. ARC RAYS CAN BURN. 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. 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 Z87. I standards. 3.b.
SAFETY PRODUCT MODEL WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION. 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. 6.a. Remove fire hazards from the welding area.
vi TABLE OF CONTENTS Page General Description ......................................................................................................................7 Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions. ....................................................
GENERAL DESCRIPTION GENERAL DESCRIPTION The OUTBACK™ 145 is designed for commercial use welder/generator applications. As a welder it provides 145 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 145 amps. As a generator it can supply up to surge watts or continuous watts of 120 / 240 volt, single-phase AC power. The machine is portable. A Kohler CH395 9.
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - OUTBACK™ 145 (K2707-2) INPUT - GASOLINE ENGINE Make/Model Description KOHLER CH395 Speed (RPM) Displacement 3750RPM High Idle 1 cylinder 4 cycle air-cooled 3400RPM Full Load gasoline 8.9 HP @ 3600 RPM(1) Aluminum Block 16.9 cu. in (277 cc) Ignition System Capacities Recoil Start; Bore x Stroke Manual Choke Fuel: 6.86 gal. (24.9L) Oil: 1.2 Qts. (1.1L) 3.1” x 2.
A-2 INSTALLATION A-2 SAFETY PRECAUTIONS LOCATION AND VENTILATION Read this entire installation section before you Whenever you use the OUTBACK™ 145, be sure that clean cooling air can flow around the machineʼs 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.
A-3 A-3 INSTALLATION STACKING OIL OUTBACK™ 145 machines CANNOT be stacked. The OUTBACK™ 145 is shipped with the engine filled with 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. TILTING Place the machine on a secure, level surface whenever you use it or store it.
A-4 A-4 INSTALLATION OUTBACK™ 145 OUTPUT CONNECTIONS 7 1 4 6 5 8 3 2 FIGURE A.1 1. 2. 3. 4. CURRENT CONTROL DIAL WELD OUTPUT TERMINALS (2) GROUND STUD CIRCUIT BREAKER 20 Amp 5. 6. 7. 8. ELECTRICAL OUTPUT CONNECTIONS RECEPTACLE - 240 VOLT, 50 AMP DUPLEX RECEPTACLE (2)- 120 VOLT, 20 AMP HOURMETER CHOKE LEVER TABLE A.1 RECOMMENDED WELDING CABLE SIZE AND LENGTH See Figure A.
A-5 A-5 INSTALLATION Cable Installation MACHINE GROUNDING Install the welding cables to your OUTBACK™ 145 as follows. See Figure A.1 for the location of parts. Because this portable engine driven welder or generator 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.). 1. The gasoline engine must be OFF to install welding cables. 2. Remove the 1/2-13 flanged nuts from the output terminals. 3.
A-6 A-6 INSTALLATION PLUGS AND HAND HELD EQUIPMENT PREMISES WIRING For further protection against electric shock, any electrical equipment connected to the generator receptacles must use a three-blade, grounded type plug or an Underwriterʼs Laboratories (UL) approved double insulated tool with a two blade plug. The OUTBACK™ 145 is not recommended for premises wiring. The OUTBACK™ 145 does not have a combined 120/240 volt receptacle and cannot be connected to a premises.
A-7 A-7 INSTALLATION CAUTION Certain Electrical devices cannot be powered to this Product. See Table A.2 TABLE A.2 ELECTRICAL DEVICE USE WITH THIS PRODUCT Type Common Electrical Devices 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 capacitative elements to fail.
B-1 B-1 OPERATION SAFETY INSTRUCTIONS WARNING WARNING ELECTRIC SHOCK can kill. ENGINE EXHAUST can kill. • Use in open, well ventilated areas or vent exhaust outside. • Do not touch electrically live parts or electrode with skin or wet clothing. • Do not stack anything on or near the engine. • Insulate yourself from work and ground. MOVING PARTS can injure. • Do not operate with doors open or guards off. • Always wear dry insulating gloves. • Stop engine before servicing.
B-2 B-2 OPERATION GRAPHIC SYMBOLS USED ON THIS EQUIPMENT OR IN THIS MANUAL WARNING / CAUTION AIR CLEANER OIL CIRCUIT BREAKER FUEL GROUND (AUXILIARY POWER) WORK CLAMP ELECTRODE WELDING ARC CHOKE OUTBACK™ 145 ®]
B-3 OPERATION GENERAL DESCRIPTION The OUTBACK™ 145 is designed for commercial use welder/generator applications. As a welder it provides 145 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 145 amps. As a generator it can supply up to surge watts or continuous watts of 120 / 240 volt, single-phase AC power. The machine is portable. A Kohler CH395 9.5 HP air cooled, OHV gasoline engine powers the welder / generator.
B-4 B-4 OPERATION CONTROLS AND SETTINGS All 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 FIGURE B.1 1 8 7 2 6 9 5 3 or 4 WELDER/GENERATOR CONTROLS See Figure B.1 for the location of the following features: 1. CURRENT CONTROL DIAL: Adjusts continuous current output.
B-5 B-5 OPERATION When the engine starts, gradually open the choke to the “RUN” position. To open the choke fully requires an engine warm-up period of several seconds to several minutes, depending on the temperature. After starting the engine, first open the choke (toward RUN) until the engine just begins to run smoothly. Then open the choke in small steps, allowing the engine to accept small changes in speed and load, until the choke is fully open (in RUN).
B-6 OPERATION WELDING OPERATION 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. ENGINE EXHAUST can kill. • 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. B-6 4.
B-7 B-7 OPERATION 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™ 145 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 control. • Maximum material thickness that can be cut is 3/8".
B-8 B-8 OPERATION TABLE B.
C-1 ACCESSORIES OPTIONS/ACCESSORIES The following options/accessories are available for your OUTBACK™145 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 No. 10 filter • Insulated electrode holder and sample electrodes 150 amp capacity.
D-1 MAINTENANCE SAFETY PRECAUTIONS WARNING • 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 maintenance requiring their removal is complete. • If guards are missing from the machine, get replacements from a Lincoln Distributor. See the EXPLODED VIEW AND PARTS LIST at the back of this manual.
D-2 MAINTENANCE To service the pre-cleaner: D-2 ENGINE ADJUSTMENTS Remove the cover. Carefully remove the foam precleaner 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 element and reinstall the air cleaner cover and wing nuts. CLEAN ENGINE: Remove dirt and debris with a cloth or a brush.
E-1 TROUBLESHOOTING E-1 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.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major Physical or Electrical Damage is Evident. 1. Contact your local Lincoln Authorized Field Service Facility. No Generator power or welding output 1. Check brushes for wear. See Maintenance section. 2. Check for loose or faulty connections at brush holders. 3. Open lead in flashing or field circuit. 4. Rheostat (R1) lead broke. 5.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE ENGINE PROBLEMS RECOMMENDED COURSE OF ACTION Recoil starter is hard to pull. 1. Crankcase may be over-filled with oil. - Check oil level. Engine will not start or starts but runs rough with low power. 1. 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.
205 MAG GENERATOR SUPPORT FRAME GROUND Y HOUR METER B LOW OIL SWITCH Y 200A 200 201 201C 202B D3 MODULE ENGINE WIRING OUTPUT RHEOSTAT 3.
17.50 .41 HOLE (4 PLACES) 21.77 BOTTOM VIEW 14.17 NOTES: N.A. CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK. 25.62 7.30 31.48 N.A. 15.75 OUTBACK™ 145 ®] DIMENSION PRINT M22562 A.02 12.
P-671 P-671 PARTS LIST FOR OUTBACK® 145 This parts list is provided as an informative guide only. It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electricʼs official Parts Book (BK-34). When ordering parts, always refer to Lincoln Electricʼs official Parts Book (BK-34) for the latest pages.
P-671-A P-671-A ILLUSTRATION OF SUB ASSEMBLIES 1 2 4 3 OUTBACK® 145 11-08-2010
P-671-A.1 P-671-A.1 Outback® 145 For Code: 11732 Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed. PAGE NO. CODE NO. 11732 1 2 3 4 Control Panel Assembly Stator & Rotor Assembly Rear Control Panel, Fuel Tank Assembly & Engine SUB ASSEMBLY PAGE NAME Optional Equipment Sub Assembly Item No.
P-671-B.1 OPTIONAL EQUIPMENT LISTING P-671-B.1 Miscellaneous Options Available for your machine are listed below: # Indicates a change this printing. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PART NUMBER Accessory Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES OUTBACK® 145
P-671-C P-671-C Cradle Tube Assembly & Roof 10A 10B 19 23 21 17 15 24 27 6A 16 6B 1 4A 4B 2A 6A 26 2B 2C 6B OUTBACK® 145 01-25-2011
P-671-C.1 P-671-C.1 # Indicates a change this printing.
P-671-D P-671-D Control Panel Assembly 10A 9A 11A 14 1 4A 13 4B 5 2A 8A 12A 15 11B 20 11D 30A 11C 32A 7A 2B 3 7B 6A 6B OUTBACK® 145 01-25-2011
P-671-D.1 P-671-D.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page.
P-671-E P-671-E Stator & Rotor Assembly 8 4A 1B 1A 3A 1C 5 6 1E 15A 7 1F 16 12B 12C OUTBACK® 145 05-22-2012
P-671-E.1 P-671-E.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. ITEM DESCRIPTION PART NO. QTY.
P-671-F P-671-F Rear Control Panel, Fuel Tank Assembly & Engine 5A 5 6 2B 23 20 2A 1A 21 1B 10A 1D 1C 10B 10C 10D 1E 22 1D 11A OUTBACK® 145 01-25-2011
P-671-F.1 P-671-F.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. ITEM DESCRIPTION PART NO. QTY.
CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. 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 possession at that time.
