RETURN TO MAIN MENU OUTBACK For use with machines having Code Numbers: ™ IM972 185 September, 2010 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 READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ARC RAYS can burn. 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.
iii iii SAFETY WELDING and CUTTING SPARKS can 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. 6.b.
iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à lʼélectrode et à la piéce sont sous tension quand la machine à souder est en marche.
v Thank You v for selecting a QUALITY product by Lincoln Electric. We want you 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 equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
vi vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions. ..............................................................................................................A-2 Location and Ventilation .................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - OUTBACK™ 185 (K2706-1) INPUT - GASOLINE ENGINE Make/Model Description KOHLER CS 12.75 Speed (RPM) 1 cylinder 3750RPM High Idle 4 cycle 1825RPM Low Idle air-cooled 3400RPM Full Load OHV gasoline 12.75 HP @ 3600 RPM Aluminum Block Displacement 21.96 cu. in (360 cc) Ignition System Capacities Electric & Recoil Start; Fuel: 6.86 gal. (24.9L) Manual Choke Oil: 1.2 Qts. (1.1L) Bore x Stroke 3.35” x 2.
A-2 INSTALLATION A-2 SAFETY PRECAUTIONS LOCATION AND VENTILATION Read this entire installation section before you start installation. Whenever you use the OUTBACK™ 185, 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.
A-3 A-3 INSTALLATION STACKING OIL OUTBACK™ 185 machines CANNOT be stacked. The OUTBACK™ 185 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™ 185 OUTPUT CONNECTIONS 2 3 10 6 9 8 7 1 4 5 1 8 4 7 9 5 6 10 3 2 FIGURE A.1 1. 2. 3. 4. 5. 6. CURRENT CONTROL DIAL WELD OUTPUT TERMINALS (2) GROUND STUD CIRCUIT BREAKERS (2) - 20 AMP CIRCUIT BREAKER 30 Amp RECEPTACLE - 240 VOLT, 50 AMP 7. DUPLEX RECEPTACLE (2)- 120 VOLT, 20 AMP 8. HOURMETER 9. ENGINE SWITCH 10. CHOKE ELECTRICAL OUTPUT CONNECTIONS 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™ 185 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™ 185 is not recommended for premises wiring.
A-7 A-7 INSTALLATION CAUTION Certain Electrical devices cannot be powered by the OUTBACK™ 185. See Table A.2 TABLE A.2 ELECTRICAL DEVICE USE WITH THE OUTBACK™ 185 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 CHOKE OIL AIR CLEANER FUEL CIRCUIT BREAKER GROUND (AUXILIARY POWER) WORK CLAMP FAST ELECTRODE WELDING ARC SLOW ENGINE OFF ENGINE START AUTO IDLE OUTBACK™ 185 ®
B-3 OPERATION 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 5700 surge watts or 5200 continuous watts of 120 / 240 volt, single-phase AC power. The machine is portable. A Kohler CS 12.
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 3 or 4 6 5 11 8 12 10 1 9 7 2 10 1 9 12 7 2 8 11 5 6 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 ENGINE OPERATION Break-in Period Starting/Shutdown Instructions 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 running hours). Change the oil after the first 5 hours of operation. See the Engine Instruction Manual for further details. Be sure all Pre-Operation Engine Service has been performed. Also, Read owners manual before starting for the first time.
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-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™ 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 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™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 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 D-2 SLIP RINGS To service the pre-cleaner: 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 Engine will not idle down to low speed. 1. Engine Switch on HIGH Idle. 2. Engine choke is not fully open. 3. External load 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 will not stay at low idle. 1.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Engine runs erratically or stops running. 1. Engine is not fully warmed-up and engine choke is in the fully open (RUN) position. 2. Engine requires service to head, carburetor, filters, oil spark plug and / or gas. 3. Oil level to low. Engine sputters but will not start. 1.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
14.17 21.60 NOTES: N.A. CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK. 17.50 25.62 6.75 7.79 29.00 31.47 OUTBACK™ 185 ® 13.50 05.31 00.92 74.13 97.7 5 7. 6 26.52 06.12 05.71 :SETON ENIGNE NI LIO HTI W YTIVARG FO RETNEC .A.N .KNAT LEUF YTPME DNA 71.41 DIMENSION PRINT M21768 B 8.25 N.A. B 5 2. 8 .A.
NOTES OUTBACK™ 185 ®
G Do not touch electrically live WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG parts or electrode with skin or wet clothing. G Insulate yourself from work and ground. G No toque las partes o los elec- trodos bajo carga con la piel o ropa mojada. G Aislese del trabajo y de la tierra. G Ne laissez ni la peau ni des vêtements mouillés entrer en contact avec des pièces sous tension. G Isolez-vous du travail et de la terre.
G Keep your head out of fumes. G Use ventilation or exhaust to G Turn power off before servic- ing. G Do not operate with panel open or guards off. remove fumes from breathing zone. G Los humos fuera de la zona de respiración. G Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. G Gardez la tête à lʼécart des fumées.
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