IM973 OUTBACK For use with machines having Code Numbers: ™ 145 December, 2011 11517 This manual covers equipment which is no longer in production by The Lincoln Electric Co. Specifications and availability of optional features may have changed. 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.
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™ 145 (K2707-1) INPUT - GASOLINE ENGINE Make/Model Description SUBARU ROBIN EX30 Speed (RPM) 1 cylinder 3750RPM High Idle 4 cycle air-cooled 3400RPM Full Load OHC gasoline 10 HP @ 3600 RPM Aluminum Block Displacement Ignition System Capacities 17.07 cu. in (287 cc) Recoil Start; Fuel: 6.86 gal. (24.9L) Manual Choke Oil: 1.1 Qts. (1.0L) Bore x Stroke 2.95” 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™ 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.
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 1 7 4 6 5 3 2 FIGURE A.1 1. 2. 3. 4. CURRENT CONTROL DIAL WELD OUTPUT TERMINALS (2) GROUND STUD CIRCUIT BREAKER 20 Amp 5. RECEPTACLE - 240 VOLT, 50 AMP 6. DUPLEX RECEPTACLE (2)- 120 VOLT, 20 AMP 7. HOURMETER ELECTRICAL OUTPUT CONNECTIONS TABLE A.1 RECOMMENDED WELDING CABLE SIZE AND LENGTH See Figure A.1 for the location of the current control dial, weld output terminals, ground stud, circuit breakers, 240 and 120 volt receptacles.
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 by 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.
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 8 1 7 2 6 5 3 or 4 WELDER/GENERATOR CONTROLS FIGURE B.1 See Figure B.1 for the location of the following features: 6. 240 VOLT RECEPTACLE: Connection point for supplying 250 volt power to operate one electrical device. 1.
B-5 B-5 OPERATION ENGINE OPERATION Stopping the Engine Starting/Shutdown Instructions Remove all welding and auxiliary power loads and allow engine to run for a few minutes to cool the engine. Be sure all Pre-Operation Engine Service has been performed. Also, Read owners manual before starting for the first time. (See INSTALLATION section) NOTE: Remove all loads connected to the AC power receptacles before starting the gasoline engine. Put the “ON/OFF” Switch in the “ON”(I) position.
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 receptacle. 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". 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.
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 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. CAUTION A slight amount of darkening and wear of the slip rings and brushes is normal.
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.
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.
21.60 25.62 NOTES: N.A. CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK. 6.75 7.79 29.00 31.47 OUTBACK™ 145 ® 13.50 A.02 DIMENSION PRINT M21768 8.25 N.A.
NOTES OUTBACK™ 145 ®
G Keep your head out of fumes. G Use ventilation or exhaust to G Turn power off before servicing. G Do not operate with panel open or guards off. remove fumes from breathing zone. G Los humos fuera de la zona de res- piración. G Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. G Gardez la tête à l’écart des fumées. G Utilisez un ventilateur ou un aspira- G Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
G Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO G Keep flammable materials away. G Wear eye, ear and body protection. G Mantenga el material combustible G Protéjase los ojos, los oídos y el electrode with skin or wet clothing. G Insulate yourself from work and ground. G No toque las partes o los electrodos bajo carga con la piel o ropa mojada. G Aislese del trabajo y de la tierra.
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