View Safety Info SVM204-A OUTBACK® 185 For use with machine code number: October, 2010 11516 Return to Master TOC View Safety Info View Safety Info Safety Depends on You Return to Master TOC Return to Master TOC RETURN TO MAIN MENU 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.
SAFETY Return to Master TOC i i WARNING 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 canchemicals 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 Gasoline Engines The Above For Diesel Engines ARC WELDING can be hazardous.
SAFETY Return to Master TOC Return to Master TOC ii 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.
SAFETY Return to Master TOC iii 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 adjcent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
SAFETY Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv iv PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. 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: 7.
Return to Master TOC Return to Master TOC Return to Master TOC v SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC.
Return to Master TOC vi SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Return to Master TOC Return to Master TOC Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations.
I - MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Master TOC A-1 TABLE OF CONTENTS - INSTALLATION SECTION A-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION Return to Master TOC Return to Section TOC A-2 A-2 TECHNICAL SPECIFICATIONS - OUTBACK® 185 (K2706-1) INPUT - GASOLINE ENGINE Make/Model Description KOHLER CS 12.75 Speed (RPM) 3750RPM High Idle 1 cylinder 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 Electric & Recoil Start; Bore x Stroke Manual Choke Capacities Fuel: 6.86 gal. (24.9L) Oil: 1.2 Qts. (1.1L) 3.35” x 2.
INSTALLATION Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A-3 SAFETY PRECAUTIONS LOCATION AND VENTILATION 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 maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.
INSTALLATION Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A-4 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.
INSTALLATION Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC A-5 A-5 OUTBACK® 185 OUTPUT CONNECTIONS 9 1 8 4 7 5 6 10 3 2 FIGURE A.1 Return to Master TOC Return to Section TOC 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.
INSTALLATION Cable Installation Return to Master TOC Return to Section TOC A-6 MACHINE GROUNDING 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 welding 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.
INSTALLATION Return to Master TOC Return to Section TOC A-7 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 Underwriter’s Laboratories (UL) approved double insulated tool with a two blade plug. The OUTBACK® 185 is not recommended for premises wiring.
INSTALLATION Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC A-8 A-8 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.
Return to Master TOC B-1 TABLE OF CONTENTS - OPERATION SECTION B-1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION Return to Master TOC Return to Section TOC B-2 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.
OPERATION Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC B-3 B-3 GRAPHIC SYMBOLS USED ON THIS EQUIPMENT OR IN THIS MANUAL WARNING / CAUTION CHOKE OIL AIR CLEANER FUEL CIRCUIT BREAKER WORK CLAMP GROUND (AUXILIARY POWER) FAST ELECTRODE WELDING ARC SLOW ENGINE OFF AUTO IDLE OUTBACK® 185 ENGINE START
OPERATION Return to Master TOC Return to Section TOC B-4 GENERAL DESCRIPTION The OUTBACK® 185 is designed for commercial use welder/generator applications. As a welder it provides 185 amps of DC constant current for welding with DC stick electrodes. A single dial lets you select a full range of welding output from 50 to 185 amps. As a generator it can supply up to surge watts or continuous watts of 120 / 240 volt, single-phase AC power. The machine is portable.
OPERATION Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC B-5 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 12 10 1 Return to Master TOC Return to Section TOC 7 2 11 5 6 3 or 4 WELDER/GENERATOR CONTROLS See Figure B.1 for the location of the following features: 1.
OPERATION Return to Master TOC Return to Section TOC B-6 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.
OPERATION Return to Master TOC Return to Section TOC B-7 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. Return to Master TOC Return to Section TOC • Use in open, well ventilated areas or vent exhaust outside. • Do not stack anything on or near the engine. MOVING PARTS can injure.
OPERATION 120V Receptacle Operation: Return to Master TOC Return to Section TOC B-8 • 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".
OPERATION Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-9 B-9 TABLE B.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC B-10 NOTES OUTBACK® 185 B-10
TABLE OF CONTENTS - ACCESSORIES SECTION C-1 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Options / Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC C-2 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.
Return to Master TOC D-1 TABLE OF CONTENTS - MAINTENANCE SECTION D-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC D-2 MAINTENANCE OUTBACK® 185 D-2
MAINTENANCE Return to Master TOC Return to Section TOC D-3 SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. Return to Master TOC • 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. OIL: Check the oil level after every 5 hours of operation or daily. BE SURE TO MAINTAIN THE OIL LEVEL.
MAINTENANCE Return to Master TOC Return to Section TOC D-4 To service the pre-cleaner: SLIP RINGS 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. Return to Master TOC Carefully place the pre-cleaner back over the filter element and reinstall the air cleaner cover and wing nuts.
MAINTENANCE Return to Master TOC Return to Section TOC D-5 D-5 1. CRADLE ASBLY, BATTERY & ROOF 2. CONTROL PANEL ASSEMBLY 3. STATOR & ROTOR ASSEMBLY 4. REAR CONTROL PANEL & FUEL TANK ASSEMBLY 5.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC D-6 NOTES OUTBACK® 185 D-6
TABLE OF CONTENTS-THEORY OF OPERATION SECTION Return to Master TOC E-1 E-1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 Engine Starting, Protection and Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2, E-3 Automatic Idle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THEORY OF OPERATION Return to Master TOC Return to Section TOC E-2 E-2 FIGURE E.
THEORY OF OPERATION Return to Master TOC Return to Section TOC E-3 E-3 FIGURE E.
THEORY OF OPERATION Return to Master TOC Return to Section TOC E-4 E-4 FIGURE E.
THEORY OF OPERATION Return to Master TOC Return to Section TOC E-5 E-5 FIGURE E.
THEORY OF OPERATION Return to Master TOC Return to Section TOC E-6 E-6 FIGURE E.
Return to Master TOC F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1 Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2 PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Master TOC Return to Section TOC F-2 TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Section TOC F-3 TROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts. Return to Master TOC Return to Section TOC CAUTION Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-4 F-4 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical damage. or electrical Contact the Lincoln Electric Service Department at 1-888-9353877.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Master TOC F-5 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS (Continued) 8. Observe the oil level indicator light while cranking the engine. If the light is blinking while cranking the engine, the oil level may be low, or the oil level system may be faulty. Contact the engine manufacturer.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-6 F-6 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS The engine runs erratically or 1. Check that the fuel valve is fully 1.
TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-7 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) Return to Master TOC RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Engine will not idle down. Weld 1. Check that the engine switch is 1. The idle solenoid may be in the “Auto” position. improperly adjusted.
TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-8 F-8 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS The engine will not go to high idle 1. Poor connection in weld circuit; 1.
TROUBLESHOOTING AND REPAIR Return to Master TOC F-9 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS 3. If voltage is present at J3-9, check for battery voltage at J3-8 (lead #224A). If voltage is not present, replace the PC board. (Continued) 4. If voltage is present at J3-8, check for battery voltage at J19 (lead #224). If voltage is not present, check leads 224 and 224A.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-10 F-10 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS 4. With the engine still running, check for about 70 to 80 VDC at the output rectifier positive and negative terminal. If voltage is not present, the rectifier is probably faulty.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-11 F-11 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS The welding arc is “cold” or weld 1. The weld boost circuit breaker 1. Perform the Engine RPM adjustment procedure.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-12 NOTES OUTBACK® 185 F-12
Return to Master TOC Return to Section TOC F-13 TROUBLESHOOTING AND REPAIR ENGINE RPM ADJUSTMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-14 ENGINE RPM ADJUSTMENT PROCEDURE (continued) FIGURE F.1 – STROBE-TACH METHOD FAN BLADE STROBE-TACH MARK PROCEDURE Strobe-Tach Method 1. Turn the engine off. 2. Place a highly visible mark on a component that rotates while the engine is running. The rotorcooling fan is a good place for this mark. See Figure F.1. Return to Master TOC 3.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-15 ENGINE RPM ADJUSTMENT PROCEDURE (continued) FIGURE F.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-16 ENGINE RPM ADJUSTMENT PROCEDURE (continued) FIGURE F.3 – VIBRATACH METHOD HIGH IDLE ADJUSTMENT LOW IDLE ADJUSTMENT TOP VIEW OF ENGINE Vibratach Method A Vibratach is used to measure the vibrations caused by the running engine. It can be positioned anywhere where the engine vibration is reasonably strong. 4.
Return to Master TOC Return to Section TOC F-17 TROUBLESHOOTING AND REPAIR THROTTLE ADJUSTMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-18 THROTTLE ADJUSTMENT PROCEDURE (continued) FIGURE F.4 – HIGH AND LOW IDLE ADJUSTMENT HIGH IDLE ADJUSTMENT LOW IDLE ADJUSTMENT TOP VIEW OF ENGINE PROCEDURE High Idle Adjustment Low Idle Adjustment Check that the linkage attaching the solenoid to the engine speed control lever is in good condition and moves freely. 1.
Return to Master TOC Return to Section TOC F-19 TROUBLESHOOTING AND REPAIR BRUSH AND SLIP RING SERVICE PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-20 F-20 BRUSH AND SLIP RING SERVICE PROCEDURE (continued) FIGURE F.5 – BRUSH HOLDER ASSEMBLY LOCATION BRUSH HOLDER ASSEMBLY SCREWS (2) Return to Master TOC Return to Section TOC LOCKING TABS COVER Return to Master TOC Return to Section TOC GENERATOR END BRACKET PROCEDURE 1. Remove the brush cover from the end of the generator. 2.
TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-21 F-21 BRUSH AND SLIP RING SERVICE PROCEDURE (continued) FIGURE F.6 – BRUSH REMOVAL AND REPLACEMENT CABLE TIE Return to Master TOC Return to Section TOC BRUSHES 9. Check for evidence of sticking brushes. Sticking brushes will normally result in the slip rings being pitted and discolored from excessive arcing.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-22 NOTES OUTBACK® 185 F-22
Return to Master TOC Return to Section TOC F-23 TROUBLESHOOTING AND REPAIR ROTOR FLASHING AND VOLTAGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-24 F-24 ROTOR FLASHING AND VOLTAGE TEST (continued) FIGURE F.7 – BRUSH AND SLIP RING LOCATIONS SLIP RINGS Return to Master TOC Return to Section TOC BRUSHES Return to Master TOC Return to Section TOC + - PROCEDURE 1. Be certain the battery is fully charged and the battery charging system is functioning normally. 2. Ensure that there is no load on either the weld or auxiliary outputs. 3. Set the output control to maximum.
Return to Master TOC Return to Section TOC F-25 TROUBLESHOOTING AND REPAIR BATTERY CHARGING SYSTEM TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-26 F-26 BATTERY CHARGING SYSTEM TEST (continued) FIGURE F.8 – CHARGING SYSTEM Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC BATTERY + - PROCEDURE WARNING DO NOT REMOVE BATTERY CABLE WHILE MACHINE IS RUNNING, OR ATTEMPT TO OPERATE THE ENGINE WITHOUT A BATTERY CONNECTED. Serious damage to the PC board may result. Return to Master TOC Return to Section TOC 1.
Return to Master TOC Return to Section TOC F-27 TROUBLESHOOTING AND REPAIR STATOR VOLTAGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-28 TROUBLESHOOTING AND REPAIR F-28 STATOR VOLTAGE TEST (continued) FIGURE F.9 – HIGH AND LOW IDLE ADJUSTMENT HIGH IDLE ADJUSTMENT LOW IDLE ADJUSTMENT TOP VIEW OF ENGINE PROCEDURE 1. Verify that the engine RPM is normal. See the Engine RPM Adjustment Procedure. 2.
Return to Master TOC Return to Section TOC F-29 TROUBLESHOOTING AND REPAIR ROTOR RESISTANCE AND GROUND TEST (STATIC) WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-30 F-30 ROTOR RESISTANCE AND GROUND TEST (STATIC) (continued) FIGURE F.10 – ROTOR RESISTANCE SLIP RINGS Return to Master TOC Return to Section TOC BRUSHES Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC + - PROCEDURE 2. Remove the plastic cover from the end of the generator. See Brush and Slip Ring Service Procedure. 6. Measure the resistance to ground.
Return to Master TOC Return to Section TOC F-31 TROUBLESHOOTING AND REPAIR ROTOR RESISTANCE AND GROUND TEST (DYNAMIC) WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-32 F-32 ROTOR RESISTANCE AND GROUND TEST (DYNAMIC) (continued) FIGURE F.11 – BRUSH AND SLIP RING LOCATIONS SLIP RINGS Return to Master TOC Return to Section TOC BRUSHES Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC + - PROCEDURE 5. Start the engine and run it at high idle speed. The resistance should read approximately 9* ohms at 77°F. (25°C.
Return to Master TOC Return to Section TOC F-33 TROUBLESHOOTING AND REPAIR STATOR SHORT CIRCUIT AND GROUND TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-34 STATOR SHORT CIRCUIT AND GROUND TEST (continued) PROCEDURE 1. Perform Case Cover Removal Procedure. 2. Disconnect anything that may be connected to the auxiliary receptacles or the weld output terminals. 3. Disconnect and isolate GND-C lead from the ground stud on the control panel front. See wiring diagram. Return to Master TOC Return to Section TOC 4.
Return to Master TOC Return to Section TOC F-35 TROUBLESHOOTING AND REPAIR WELD BOOST SYSTEM TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-36 TROUBLESHOOTING AND REPAIR F-36 WELD BOOST SYSTEM TEST (continued) FIGURE F.12 – HIGH AND LOW IDLE ADJUSTMENT HIGH IDLE ADJUSTMENT LOW IDLE ADJUSTMENT Return to Master TOC Return to Section TOC TOP VIEW OF ENGINE PROCEDURE 1. Check that the CB4 circuit breaker is not tripped. 2. Check that the battery is fully charged and in good condition. 3. Set the output dial to the Maximum position. 4.
Return to Master TOC Return to Section TOC F-37 TROUBLESHOOTING AND REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-38 TROUBLESHOOTING AND REPAIR F-38 CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.13 – CASE COVER REMOVAL CASE SCREWS CASE SCREWS PROCEDURE 1. Using a 3/8” wrench, remove all screws from the top of the red sheet metal cover. 2. Lift the top cover off of the machine 3.
Return to Master TOC Return to Section TOC F-39 TROUBLESHOOTING AND REPAIR FUEL TANK AND ENCLOSURE REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-40 F-40 FUEL TANK AND ENCLOSURE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.
Return to Master TOC Return to Section TOC F-41 TROUBLESHOOTING AND REPAIR FUEL TANK AND ENCLOSURE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-42 NOTES OUTBACK® 185 F-42
Return to Master TOC Return to Section TOC F-43 TROUBLESHOOTING AND REPAIR CONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-44 CONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.16 – CONTROL BOX REMOVAL FUEL TANK CONTROL BOX END PANEL 3/8’ SCREWS PROCEDURE 1. Perform the Case Cover Removal Procedure. 2. Using the 7/16” wrench, loosen battery mounting bracket. See Figure F.16. 3. Remove the battery. 4.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-45 TROUBLESHOOTING AND REPAIR FIGURE F.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-46 NOTES OUTBACK® 185 F-46
Return to Master TOC Return to Section TOC F-47 TROUBLESHOOTING AND REPAIR STATOR REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-48 F-48 STATOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.18 – STATOR REMOVAL HAMMER TAPPING POINTS TOLERANCE RING Return to Master TOC Return to Section TOC BRUSH ASSEMBLY CAST END BRACKET Return to Master TOC Return to Section TOC BEARING BRACKET END COVER PROCEDURE 1. Perform the Control Box Removal Procedure. 2. Remove the brushes. See the Brush and Slip Ring Service Procedure. 3.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-49 TROUBLESHOOTING AND REPAIR STATOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.19 – NUTS & RUBBER ENGINE MOUNTS RUBBER ENGINE MOUNT “OTHER ENGINE MOUNTS NOT VISIBLE FROM THIS ANGLE” Installing the stator assembly: 1. If the rotor has been removed, it must be replaced before installation of the stator assembly. See the Rotor Removal Procedure.
Return to Master TOC Return to Section TOC F-50 TROUBLESHOOTING AND REPAIR F-50 STATOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.20 – STATOR LOCATION Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TOLERANCE RING STATOR 10. Check the air gap between the rotor and the stator. Feeler gages are inserted between the rotor and stator through the brush access opening. A .010 gage should be able to pass completely through the air gap and a .
Return to Master TOC Return to Section TOC F-51 TROUBLESHOOTING AND REPAIR ROTOR REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-52 F-52 ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.21 – ROTOR LOCATION ROTOR Return to Master TOC Return to Section TOC THROUGH BOLT PROCEDURE IMPORTANT 1. Perform the Stator Removal Procedure. 2. Remove the long through-bolt from the bearing end of the rotor. (An impact wrench works best for removing this through-bolt). See Figure F.21. 3.
TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-53 RETEST AFTER REPAIR PROCEDURE No-load test values High idle (No load) RPM: 3700-3800 RPM (61.7 – 63.3 Hz) Low idle RPM: 2250-2500 RPM (37.5 – 41.7 Hz) Weld terminal open Circuit Voltage (OCV): Return to Master TOC Return to Section TOC Weld control at maximum: 70 – 80 VDC Weld control at minimum: 45 – 60 VDC Full load test values: Weld output control set to maximum.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-54 NOTES OUTBACK® 185 F-54
TABLE OF CONTENTS - DIAGRAM SECTION Return to Master TOC G-1 G-1 Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram - Complete Machine Code 11516 (L13878) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2 Schematic – Complete Machine Code 11516 (G6205) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Master TOC Return to Section TOC G-2 G-2 ElEcTrical DiaGramS WiriNG DiaGram - cOmplETE machiNE cODE 11516 (l13878) WIRING DIAGRAM - OUTBACK 185 77 GND-J GROUND STUD ON CONTROL PANEL FRONT 76 R1 75 Return to Master TOC Return to Section TOC OIL LEVEL MODULE BLUE 224A LOW OIL INDICATOR L.E.D.
Return to Master TOC G-3 ElEcTrical DiaGramS SchEmaTic - cOmplETE machiNE cODE 11516 (G6205) G6205 Return to Section TOC G-3 ENGINEERING CONTROLLED MANUFACTURER: No CHANGE DETAIL: RELEASED A.02 FROM X.
SchEmaTic - FiElD cONTrOl / iDlE pc BOarD (G4793-1) J2 5.1K 5W +10V 4 R27 C18 0.1uF 50V 100K C17 0.022uF 50V R43 750 3 2 2901N 100K CR1 CR1 12VDC CASE J3 +10V COM 10 2901N R67 D19 0.2A 30V 10K J1 J1 R69 475 7.5K 10 14 X5 R45 1K 224N 10 R48 475 8 X5 224N R47 475 NC 9 C23 47pF 100V 2.67K 5 C13 6 820pF 50V X7 7 9 R55 4.32K 33074A C26 0.1uF 50V NC 2 NC 8 4 2 1 3 R62 10K C33 100pF 100V C32 0.0047uF 50V 51.