SVM204-A
October, 2010
Ā®
OUTBACK 185
For use with machine code number: 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. DOź¢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.
SERVICE MANUAL
Copyright Ā© Lincoln Global Inc.
ā¢ World's Leader in Welding and Cutting Products ā¢
ā¢ Sales and Service through Subsidiaries and Distributors Worldwide ā¢
Cleveland, Ohio 44117-1199 U.S.A. TEL: 1.888.935.3877 FAX: 216.486.1751 WEBź¢SITE: www.lincolnelectric.com
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SAFETY
ELECTRIC SHOCK can kill.
ARC RAYS can burn.
3.a. The electrode and work (or ground) circuits
are electrically āhotā when the welder is on.
Do not touch these āhotā 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. 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.
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.
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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
ā¢ Semiautomatic DC Constant Voltage (Wire) Welder.
ā¢ DC Manual (Stick) Welder.
ā¢ AC Welder with Reduced Voltage Control.
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically āhotā.
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 ven-
tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre-
cautions are also required when welding on galvanized
steel.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
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 specific
welding procedure and application involved. Worker expo-
sure level should be checked upon installation and periodi-
cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically āhotā 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.
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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturerās instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerās safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
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SAFETY
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
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.
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to āSafety in Welding and Cuttingā (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
ā¢Away from areas where they may be struck or subjected to
physical damage.
ā¢A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
6.c. 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.
7.d. Never allow the electrode, electrode holder or any other
electrically āhotā parts to touch a cylinder.
6.d. 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 explosion even though they have
been ācleanedā. For information, purchase āRecommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substancesā, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
āPrecautions for Safe Handling of Compressed Gases in
Cylinders,ā available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. 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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.g. 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 circuits. This can
create fire hazards or overheat lifting chains or cables until
they fail.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerās
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerās recommendations.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B ā Standard for Fire Prevention
During Welding, Cutting and Other Hot Workā, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
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SAFETY
6. Eloigner les matƩriaux inflammables ou les recouvrir afin de
PRĆCAUTIONS DE SĆRETĆ
prĆ©venir tout risque dāincendie dĆ» aux Ć©tincelles.
Pour votre propre protection lire et observer toutes les instructions
et les prƩcautions de sƻretƩ specifiques qui parraissent dans ce
manuel aussi bien que les prƩcautions de sƻretƩ gƩnƩrales suiv-
antes:
7. Quand on ne soude pas, poser la pince Ć une endroit isolĆ© de
la masse. Un court-circuit accidental peut provoquer un
Ć©chauffement et un risque dāincendie.
8. Sāassurer que la masse est connectĆ©e le plus prĆ©s possible de
la zone de travail quāil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dāautres endroits
ƩloignƩs de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
cĆ¢bles de grue, ou autres circuits. Cela peut provoquer des
risques dāincendie ou dāechauffement des chaines et des
cĆ¢bles jusquāĆ ce quāils se rompent.
SĆ»retĆ© Pour Soudage A LāArc
1. Protegez-vous contre la secousse Ć©lectrique:
a. Les circuits Ć lāĆ©lectrode et Ć la piĆ©ce sont sous tension
quand la machine Ć souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vƩtements mouillƩs. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trĆ©s attention de bien sāisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
les positions assis ou couchƩ pour lesquelles une grande
partie du corps peut ĆŖtre en contact avec la masse.
c. Maintenir le porte-Ć©lectrode, la pince de masse, le cĆ¢ble de
soudage et la machine Ć souder en bon et sĆ»r Ć©tat defonc-
tionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliƩrement important pour le soudage de tƓles
galvanisƩes plombƩes, ou cadmiƩes ou tout autre mƩtal qui
produit des fumeƩs toxiques.
10. Ne pas souder en prƩsence de vapeurs de chlore provenant
dāopĆ©rations de dĆ©graissage, nettoyage ou pistolage. La
chaleur ou les rayons de lāarc peuvent rĆ©agir avec les vapeurs
du solvant pour produire du phosgƩne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-Ć©lectrode dans lāeau pour le
refroidir.
e. Ne jamais toucher simultanƩment les parties sous tension
des porte-Ć©lectrodes connectĆ©s Ć deux machines Ć souder
parce que la tension entre les deux pinces peut ĆŖtre le total
de la tension Ć vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sƻretƩ, voir
le code āCode for safety in welding and cuttingā CSA Standard
W 117.2-1974.
f. Si on utilise la machine Ć souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-Ć©lectrode sāapplicuent aussi au pistolet de
soudage.
PRĆCAUTIONS DE SĆRETĆ POUR
LES MACHINES Ć SOUDER Ć
TRANSFORMATEUR ET Ć
REDRESSEUR
2. Dans le cas de travail au dessus du niveau du sol, se protƩger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le cĆ¢ble-Ć©lectrode autour de nāimporte quelle partie du
corps.
3. Un coup dāarc peut ĆŖtre plus sĆ©vĆØre quāun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant appropriƩ ainsi
quāun verre blanc afin de se protĆ©ger les yeux du rayon-
nement de lāarc et des projections quand on soude ou
quand on regarde lāarc.
1. Relier Ć la terre le chassis du poste conformement au code de
lāĆ©lectricitĆ© et aux recommendations du fabricant. Le dispositif
de montage ou la piece Ć souder doit ĆŖtre branchĆ© Ć une
bonne mise Ć la terre.
b. Porter des vĆŖtements convenables afin de protĆ©ger la peau
de soudeur et des aides contre le rayonnement de lāarc.
c. ProtĆ©ger lāautre personnel travaillant Ć proximitĆ© au
soudage Ć lāaide dāĆ©crans appropriĆ©s et non-inflammables.
2. Autant que possible, Iāinstallation et lāentretien du poste seront
effectuƩs par un Ʃlectricien qualifiƩ.
3. Avant de faires des travaux Ć lāinterieur de poste, la debranch-
er Ć lāinterrupteur Ć la boite de fusibles.
4. Des gouttes de laitier en fusion sont Ć©mises de lāarc de
soudage. Se protĆ©ger avec des vĆŖtements de protection libres
de lāhuile, tels que les gants en cuir, chemise Ć©paisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sĆ»retĆ© Ć leur place.
5. Toujours porter des lunettes de sƩcuritƩ dans la zone de
soudage. Utiliser des lunettes avec Ć©crans lateraux dans les
zones oĆ¹ lāon pique le laitier.
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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. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturerās
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work com-
plete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equip-
ment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
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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
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturerās recommenda-
tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip-
ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturerās recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturerās recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con-
nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance,
selected according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-
1
tions.
_________________________
1
Portions of the preceding text are contained in EN 60974-10: āElectromagnetic Compatibility (EMC) prod-
uct standard for arc welding equipment.ā
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-591
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A-1
TABLE OF CONTENTS - INSTALLATION SECTION
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Pre-Operation Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Electrical Devices used with the OUTBACKĀ® 185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
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INSTALLATION
TECHNICAL SPECIFICATIONS - OUTBACKĀ® 185 (K2706-1)
INPUT - GASOLINE ENGINE
Make/Model
Description
Speed (RPM)
Displacement
Ignition
System
Capacities
KOHLER
CS 12.75
1 cylinder
4 cycle
air-cooled
3750RPM High Idle 21.96 cu. in
1825RPM Low Idle (360 cc)
3400RPM Full Load
Electric & Recoil
Start;
Fuel: 6.86 gal.
(24.9L)
OHV gasoline
12.75 HP @
3600 RPM
Aluminum Block
w/ Cast Iron Sleeve
Bore x Stroke
Manual
Choke
Oil: 1.2 Qts.
(1.1L)
3.35ā x 2.48ā
(85 mm x 63mm)
RATED OUTPUT - WELDER
DUTY CYCLE
AMPS @ DC CONSTANT CURRENT
VOLTS @ RATED AMPERES
100
130
150
185
100%
60%
20%
25
25
25
---
MAX OUTPUT
OUTPUT -WELDER AND GENERATOR
Welding Ranges
Welding Open Circuit Voltage
AC Auxiliary Power
4600 Watts 115V 1PH
100% Duty Cycle
50 - 185 Amps DC
80 VDC Max.
5700 Peak Watts
5200 Continuous Watts
120 / 230 V 1PH
PHYSICAL DIMENSIONS
DEPTH
HEIGHT
25.47 in.
WIDTH
WEIGHT
310.0 lbs.
140.6 kg
21.12 in.
536.45 mm
31.48 in.
799.59 mm
646.94 mm
OPERATINGź¢TEMPERATURE RANGE
STORAGE TEMPERATURE RANGE
0Ā° F TO 104Ā° F (-18Ā° C TO 40Ā° C)
-40Ā° F TO 131Ā° F (-40Ā° C TO 55Ā° C)
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A-3
INSTALLATION
SAFETY PRECAUTIONS
LOCATION AND VENTILATION
Read this entire installation section before you
start installation.
Whenever you use the OUTBACKĀ® 185, be sure that clean
cooling air can flow around the machineās 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.
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.
The OUTBACKĀ® 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.
Hazards of Electric Shock, Engine
Exhaust & Moving Parts
Always operate the OUTBACKĀ® 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.
WARNING
STORING
ELECTRIC SHOCK can kill.
ā¢ Do not touch electrically live parts
or electrode with skin or wet cloth-
ing.
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 activities,
moving vehicles and other hazards.
ā¢ Insulate yourself from work and
ground.
2. If 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 carburetor.
4. While the engine is still warm, drain the oil and refill with
fresh 10W30 oil.
ā¢ Always wear dry insulating gloves.
ENGINE EXHAUST can kill.
ā¢ Use in open, well ventilated areas
or vent exhaust outside.
ā¢ Do not stack anything on or near
the engine.
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 cylinder and cylinder
head fins and housing, rotating screen, and muffler
areas.
MOVING PARTS can injure.
ā¢ Do not operate with doors open or
guards off.
ā¢ Stop engine before servicing.
ā¢ Keep away from moving parts.
7. Store in a clean, dry area.
Only qualified personnel should install, use, or
service this equipment.
OUTBACKĀ® 185
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A-4
A-4
INSTALLATION
OIL
STACKING
The OUTBACKĀ® 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.
OUTBACKĀ® 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.
FUEL
Fill the fuel tank with clean, fresh, regular grade (mini-
mum 87 octane lead free gasoline. DOź¢NOTź¢MIX OIL
WITHź¢GAS. The OUTBACKĀ® 185 capacity is approxi-
mately 6.8 gallons (25.74 Liter). DO NOT OVERFILL,
allow room in the fuel tank for fuel expansion.
The gasoline engine is designed to run in a level posi-
tion for best performance. It 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.
SPARK ARRESTER
LIFTING
The OUTBACKĀ® 185 should be lifted by two people.
LowLiftā¢ grab bars on both ends make lifting easi-
er.
Some federal, state or local laws may require gasoline
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.
PRE-OPERATION ENGINE SERVICE
Read and understand the engine operating and
maintenance instructions supplied with this machine
before you operate the OUTBACKĀ® 185.
CAUTION
An incorrect additional arrester may lead to dam-
age to the engine or adversely affect performance.
------------------------------------------------------------------------
WARNING
ā¢ Keep hands away from muffler or HOT engine
parts.
ā¢ Stop the engine when fueling.
ā¢ Do not smoke when fueling.
ā¢ Remove fuel cap slowly to release pressure.
ā¢ Do not overfill tank.
ā¢ Wipe up spilled fuel and allow fumes to clear
before starting engine.
ā¢ Keep sparks and flame away from tank.
------------------------------------------------------------------------
OUTBACKĀ® 185
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A-5
A-5
INSTALLATION
OUTBACKĀ® 185 OUTPUT CONNECTIONS
1
4
5
8
7
9
6
10
3
2
FIGURE A.1
1. CURRENT CONTROL DIAL
2. WELD OUTPUT TERMINALS (2)
3. GROUND STUD
7. DUPLEX RECEPTACLE (2)- 120 VOLT, 20 AMP
8. HOURMETER
9. ENGINE SWITCH
4. CIRCUIT BREAKERS (2) - 20 AMP
5. CIRCUIT BREAKER 30 Amp
6. RECEPTACLE - 240 VOLT, 50 AMP
10. CHOKE
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 break-
ers, 240 and 120 volt receptacles.
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
WELDING CABLE CONNECTIONS
Cable
Length
125 Amps
30% Duty Cycle
Cable Size and Length
0-50 ft (0-15m)
50-100 ft (15-30 m)
100-150 ft (30-46 m)
150-200 ft (46-61 m)
200-250 ft (61-76m)
6 AWG
5 AWG
3 AWG
2 AWG
1 AWG
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 dis-
tance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
OUTBACKĀ® 185
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A-6
A-6
INSTALLATION
Cable Installation
MACHINE GROUNDING
Install the welding cables to your OUTBACKĀ® 185 as
Because this portable engine driven welder or genera-
tor 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 weld-
ing cables.
To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power,
must:
2. Remove the 1/2-13 flanged nuts from the output
terminals.
a) be grounded to the frame of the welder using a
3. Connect the electrode holder and work cables to
the weld output terminals. Normally, the electrode
cable is connected to the positive (+) output stud.
grounded type plug
or
b) be double insulated
4. Tighten the flanged nuts securely.
When this welder is mounted on a truck or trailer, the
stud must be securely con-
machine grounding
nected to the metal frame of the vehicle.
5. Be certain that the metal piece you are welding
(the āworkā) is securely connected to the work
clamp and cable.
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 insulated
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
6. Check and tighten the connections periodically.
CAUTION
ā¢ Loose connections will cause the output studs to
overheat and the studs may eventually melt.
stud marked with the symbol
front of the welder.
is provided on the
ā¢ Do not cross welding cables at output stud connec-
tion. Keep isolated and separate from one another.
WARNING
------------------------------------------------------------------------
DO NOT GROUND MACHINE TO A PIPE WHICH CAR-
RIES EXPLOSIVE OR COMBUSTIBLE MATERIAL.
Lincoln Electric offers a welding accessory kit with #6
this manual for more information.
------------------------------------------------------------------------
For more information on welding , see WELDING
ual.
OUTBACKĀ® 185
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A-7
A-7
INSTALLATION
PLUGS AND HAND HELD EQUIPMENT
PREMISES WIRING
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
Underwriterās Laboratories (UL) approved double insu-
lated tool with a two blade plug.
The OUTBACKĀ® 185 is not recommended for premis-
es wiring. The OUTBACKĀ® 185 does not have a com-
bined 120/240 volt receptacle and cannot be connect-
ed to a premises as described in other Lincoln litera-
ture.
The OUTBACKĀ® 185 is intended only for backup,
intermittent use power. Certain electrical devices can-
not be powered by the OUTBACKĀ® 185. Refer to
Table A.2 for these devices.
WARNING
Never operate this machine with damaged or
defective cords. All electrical equipment must be
in safe operating condition.
CIRCUIT BREAKERS
------------------------------------------------------------------------
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.
AUXILIARY POWER RECEPTACLES
The control panel of the OUTBACKĀ® 185 features
three auxiliary power receptacles:
CAUTION
ā¢
ā¢
Two 20 amp,120 volt duplex (double outlet)
receptacle.
NEVER BYPASS THE CIRCUIT BREAKERS. WITH-
OUT OVERLOAD PROTECTION, THE UNIT COULD
OVERHEAT AND/OR CAUSE DAMAGE TO THE
EQUIPMENT BEING USED.
A 50 amp, 240 volt single outlet receptacle.
------------------------------------------------------------------------
Through these receptacles the machine can supply up
to 5700 watts surge or 5200 watts continuous of single-
phase 60 Hertz AC power. The machine output volt-
ages meet UL standards and fall within Ā± 10% of the
rated voltage.
OUTBACKĀ® 185
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A-8
A-8
INSTALLATION
CAUTION
Certain Electrical devices cannot be powered by the OUTBACKĀ® 185. See Table A.2
TABLE A.2
ELECTRICAL DEVICE USE WITH THE OUTBACKĀ® 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 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
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 A OUTBACKĀ® 185.
The Lincoln Electric Company is not responsible for any damage to electrical components
improperly connected to a OUTBACKĀ® 185.
OUTBACKĀ® 185
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B-1
B-1
TABLE OF CONTENTS - OPERATION SECTION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Operational Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Welding Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Welder/Generator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Welding Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Electrode selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Auxiliary Power Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
OUTBACKĀ® 185
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B-2
B-2
OPERATION
SAFETY INSTRUCTIONS
WARNING
WARNING
ELECTRIC SHOCK
can kill.
ENGINE EXHAUST can kill.
ā¢ Use in open, well ventilated areas
or vent exhaust outside.
ā¢ Do not touch electrically live parts
or electrode with skin or wet
clothing.
ā¢ Do not stack anything on or near
the engine.
ā¢ Insulate yourself from work and
ground.
MOVING PARTS can injure.
ā¢ Do not operate with doors open or
guards off.
ā¢ Always wear dry insulating
gloves.
ā¢ Stop engine before servicing.
ā¢ Keep away from moving parts.
FUMES AND GASES
can be dangerous.
Only qualified personnel should install, use, or
service this equipment.
ā¢ Keep your head out of fumes.
Observe additional Safety Guidelines detailed
throughout this manual.
ā¢ Use ventilation or exhaust to
remove fumes from breathing
zone.
WELDING SPARKS
can cause fire or
explosion
ā¢ Keep flammable material away.
ā¢ Do not weld on containers that
have held combustibles.
ARC RAYS
can burn.
ā¢ Wear eye, ear and body
protection.
OUTBACKĀ® 185
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B-3
B-3
OPERATION
GRAPHIC SYMBOLS USED ON THIS EQUIPMENT OR IN THIS MANUAL
WARNING /
CAUTION
CHOKE
AIR CLEANER
OIL
CIRCUIT
BREAKER
FUEL
GROUND
(AUXILIARY
POWER)
WORK CLAMP
FAST
ELECTRODE
WELDING ARC
SLOW
ENGINE OFF
ENGINE START
AUTO IDLE
OUTBACKĀ® 185
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B-4
B-4
OPERATION
GENERAL DESCRIPTION
DESIGN FEATURES AND
ADVANTAGES
The OUTBACKĀ® 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.
ā¢ 185 amp DC constant current welding for stick
electrodes.
ā¢ Lightweight / portable.
ā¢ Full range, continuous welding output control with
a single knob.
As a generator it can supply up to surge watts or con-
tinuous watts of 120 / 240 volt, single-phase AC power.
The machine is portable.
ā¢ Automatic shutdown under low oil level condition.
ā¢ Hour Meter Standard.
ā¢ Surge watts or Watts of continuous 120 / 240 volt
single phase AC auxiliary power.
ā¢ Kohler CS 12.75 HP overhead cam air-cooled
gasoline engine. Smooth running, long life.
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
WELDING CAPABILITY
Welder
The OUTBACKĀ® 185 provides excellent constant cur-
rent DC welding output for stick (SMAW) welding.
The OUTBACKĀ® 185 rated 185 amps, 20 VDC at 10%
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 currents. For exam-
ple, you can load the welder to 120 amps for ten min-
utes out of ten for a 100% duty cycle.
Generator
The OUTBACKĀ® 185 gives smooth AC generator out-
put for continuous auxiliary power usage within the
engine manufacturerās required maintenance recom-
mendations.
The current is continuously variable from 50 to 185
amps DC. The OUTBACKĀ® 185 can, therefore, weld
with all 3/32ā, 1/8ā and most 5/32ā diameter Lincoln DC
electrodes.
OPERATIONAL FEATURES AND
CONTROLS
LIMITATIONS
The OUTBACKĀ® 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 machineās 50 to
185 amp range.
ā¢ The OUTBACKĀ® 185 is not recommended for any
processes besides those that are normally per-
formed using stick welding (SMAW) procedures.
ā¢ The OUTBACKĀ® 185 is not recommended for pipe
thawing.
The gasoline engine controls include a recoil starter,
about starting, running, stopping, and breaking in the
gasoline engine.
ā¢ 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 EQUIP-
MENT WHILE YOU ARE WELDING.
OUTBACKĀ® 185
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B-5
B-5
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
10
1
9
7
2
12
8
11
5
6
3 or 4
FIGURE B.1
10. HOUR METER: Records the time that the engine has
run for maintenance purposes.
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.
11. 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.
2. 30 AMP CIRCUIT BREAKER: Provide separate over-
load current protection for the 120 Volt and 240 Volt
Receptacles
When placed in the āOFFā
position, the ignition
3. WELD POSITIVE OUTPUT TERMINAL: Provides the
connection point for either the electrode holder or the
work cable. (Because the OUTBACKĀ® 185 is a DC
output machine, either output terminal can be used for
either cable.)
circuit is de-energized to shut down the engine.
When held in the āSTARTā
position, the engine
starter motor is energized.
When in āHIGH IDLEā (
will run continuously at high idle.
) position, the engine
4. WELD NEGATIVE OUTPUT TERMINAL: Provides the
connection point for either the electrode holder or the
work cable. (Because the OUTBACKĀ®185 is a DC out-
put machine, either output terminal can be used for
either cable.)
When in āAUTO IDLEā (
engine will run continuously and the idler operates as
follows:
/
) position, the
5. GROUND STUD: Provides a connection point for con-
necting the machine case to earth ground for the safest
grounding procedure.
ā¢ 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.
6. CIRCUIT BREAKER: Provides overload protection for
weld output terminals.
7. CIRCUIT BREAKERS (2): Provide separate overload cur-
rent protection for the 120 volt and 240 volt receptacles
ā¢ Auxiliary Power
With the engine running at low idle and auxiliary
power for lights or 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.
8. 240 VOLT RECEPTACLE: Connection point for supply-
ing 250 volt power to operate one electrical device.
9. 120 VOLT DUPLEX RECEPTACLES (2): Connection
point for supplying 120 volt power to operate devices
needed for maintenance purposes.
OUTBACKĀ® 185
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B-6
B-6
OPERATION
Break-in Period
ENGINE OPERATION
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.
Starting/Shutdown Instructions
Be sure all Pre-Operation Engine Service has been
performed. Also, Read owners manual before starting
Remove all loads connected to the AC power recepta-
cles. Before starting, first open the fuel shutoff valve.
CAUTION
IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE
UNIT SHOULD BE SUBJECTED TO MODERATE
LOADS, WITHIN THE RATING OF THE MACHINE.
AVOID LONG IDLE RUNNING PERIODS. REMOVE
LOADS AND ALLOW ENGINE TO COOL SEVERAL
MINUTES AT LOW IDLE BEFORE SHUTDOWN.
-----------------------------------------------------------------------
Always pull the choke control out when starting the
engine; cold, warm or hot.
Turn the engine switch to the āStartā
position and
crank the engine until it starts, slowly return the choke
control to the full āinā position (choke open), and turn
the switch to the Auto Idle (
/
) position.
Do not turn the switch to the āstartā position while the
engine is running because this will cause damage to
the ring gear and/or starter motor.
Low Oil Sensing
This engine has a built in sensor which responds to low
oil level (not pressure). When activated, the system
will shut the engine down. The engine will not restart
until sufficient oil is added. Check oil level frequently
and add oil as required to the full mark on the dipstick.
DO NOT OVERFILL.
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
āOffā (
Typical Fuel Consumption
) position.
KOHLER CS 12.75 HP
WARNING
NO LOAD.
2250 R.P.M
.20 GALLONS/HOUR
.75 ( LITERS/HOUR)
Close the fuel valve when the machine is
transported to prevent fuel leakage from
the carburetor.
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
.99 GALLONS/HOUR
3.74 ( LITERS/HOUR)
OUTBACKĀ® 185
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B-7
B-7
OPERATION
4. Insert the electrode into the electrode holder.
5. Set the current control dial to the desired output
current .
WELDING OPERATION
6. Start the gasoline engine.
WARNING
ELECTRIC SHOCK can kill.
the manual.
7. Strike an arc and begin welding.
ā¢ Do not touch electrically live parts
or electrode with skin or wet cloth-
ing.
AFTER YOU FINISH THE WELD:
ā¢ Insulate yourself from work and
ground.
ā¢ Always wear dry insulating gloves.
ENGINE EXHAUST can kill.
TION in this section of the manual.
2. Allow the electrode and work to cool completely.
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 OUTBACKĀ® 185 for
welding, disconnect the welding cables from the weld
output terminals. Reattach the flange nuts and leave
them on the terminals.
ā¢ Use in open, well ventilated areas
or vent exhaust outside.
ā¢ Do not stack anything on or near
the engine.
MOVING PARTS can injure.
ā¢ Do not operate with doors open or
guards off.
For DC+ welding, the electrode cable is to be connected
to the ā+ā output stud and work cable to the ā-ā output
stud. (For DC- welding, reverse these connections.)
ā¢ Stop engine before servicing.
ā¢ Keep away from moving parts.
Only qualified personnel should install, use, or
service this equipment.
Semi-automatic Wire Welding with a Lincoln Wire
Feeder/Welder
The OUTBACKĀ® 185 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.
The OUTBACKĀ® 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.
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.
If 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
give you the recommended dial settings based on the
thickness of the work and the size and type of rod
youāre using.
Plasma Cutting with Lincoln Pro-Cut 25.
The OUTBACKĀ® 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 fol-
lowing conditions:
TO USE THE OUTBACKĀ® 185 FOR WELDING:
1. Set the Current Control on the OUTBACKĀ® 185 to the
185 amp position. (Higher Settings may result in a
shutdown of the Pro-Cut 25.)
1. Remove the flange nuts from the weld output ter-
minals and place the work and electrode welding
B.1a. Replace and tighten the flange nuts
2. Leave the "ON/OFF" switch on the Pro-Cut "OFF"
until the OUTBACKĀ® 185 has been started and is at
full operating speed.
securely. Be sure the connections are tight.
3. Attach the work clamp securely to the work you are
welding.
OUTBACKĀ® 185
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B-8
B-8
OPERATION
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
amps will need 240 watts of power (120 x 2 = 240).
120V Receptacle Operation:
ā¢ Set the Output Control on the Pro-Cut 25 no higher
than the 15 amp position.( Higher settings may cause
circuit breaker on the OUTBACKĀ® 185 to trip.)
ā¢ Maximum material thickness that can be cut is 1/4".
CATIONS, to determine the wattage requirements of
the most common types of loads you can power with
the OUTBACKĀ® 185 Be sure to read the notes at the
bottom of the table.
240V Receptacle Operation:
ā¢ The Pro-Cut 25 may be used for its full range of con-
trol.
ā¢ Maximum material thickness that can be cut is 3/8".
TO USE THE OUTBACKĀ® 185 AS AN AUXILIARY
POWER SUPPLY:
AUXILIARY POWER OPERATION
TION in this section of the manual.
WARNING
2. Set the current control dial on the output control
Be sure that any electrical equipment plugged into the
generator AC power receptacles can withstand a Ā±10%
voltage and a Ā±5% frequency variation. Some elec-
tronic devices cannot be powered by the OUTBACKĀ®
WITH THE OUTBACKĀ® 185, in the INSTALLATION
section of this manual.
3. Plug the load(s) into the appropriate 120 volt or
240 volt power receptacle.
NOTE: During welding, the maximum generator out-
put for auxiliary loads is 100 watts.
GENERAL INFORMATION
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.
The OUTBACKĀ® 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.
TABLE B.2
ELECTRODE SELECTION GUIDE
CURRENT RANGE (AMPS)
AWS
CLASSIFICATION ELECTRODE TYPE
ELECTRODE
POLARITY
3/32 SIZE
1/8 SIZE
75-135
70-110
55-110
100-135
90-125
90-125
75-110
80-110
50-150
5/32 SIZE
90-175
80-145
105-135
145-180
125-185
130-185
95-150
E6010
E6011
E6011
E6013
E7018
E7018
FLEETWELDĀ® 5P
FLEETWELDĀ® 35
FLEETWELDĀ® 180
FLEETWELDĀ® 37
EXCALIBURĀ® 7018
JETWELDĀ® LH-73
DC+
DC+
DC+
DCĀ±
DC+
DC+
DC+
DC+
DC+
50-75
50-75
50-80
70-95
70-100
65-85
50-80
50-80
-
E708-17 & E308L-17 BLUE MAXĀ® 308/308L AC-DC
ENi-CI
-
SOFTWELDĀ® 99Ni
WEARSHIELDĀ® ABR
100-140
50-185
1/8 AND
THINNER
SHEET THICKNESS
1/8 AND THICKER
OUTBACKĀ® 185
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B-9
B-9
OPERATION
TABLE B.3
AUXILIARY POWER APPLICATIONS
Suggested Power Applications
Running Watts
(Continuous)
*Start-up Watts
(Peak)
*Air Compressor - 1 HP
*Air Compressor - 3/4 HP
*Airless Sprayer - 1/3 HP
Chain Saw
2,000
1,250
600
4,000 - 8,000
3,100 - 5,000
1,500 - 2,400
1,200
1,200
1,000
500
Circular Saw
Coffee Maker
*Deep Freezer
750 - 2,000
*Electric Motor - 1 HP
Electric Range (1 element)
Electric Skillet
1,000
1,500
1,250
1,200
600
2,500 - 4,000
*Furnace Fan - 1/3 HP
Portable Grinder (4 1/2ā)
Portable Grinder (7ā)
Halogen Work Light
Hand Drill - 1/4ā
3,000 - 4,800
2,000
500
500
Hand Drill - 3/8ā
700
1500 Watt Heater
Hedge Trimmer
1,750
450
Light Bulb
100
Reciprocating Saw
Radial Arm Saw
900
2,600
50
Radio
*Refrigerator/Freezer (small)
Slow Cooker
600
1,500 - 2,400
200
*Submersible Pump - 1 HP
*Sump Pump
1,000
600
2,500 - 4,000
1,500 - 2,400
Toaster
1,100
500
Weed Trimmer
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.
OUTBACKĀ® 185
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B-10
B-10
NOTES
OUTBACKĀ® 185
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C-1
C-1
TABLE OF CONTENTS - ACCESSORIES SECTION
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Options / Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
OUTBACKĀ® 185
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C-2
C-2
ACCESSORIES
OPTIONS/ACCESSORIES
The following options/accessories are available for
your OUTBACKĀ®185 from your local Lincoln
Distributor:
Accessory Kit (K875) ā Includes the following:
ā¢ Twenty feet (6.1 meters) of #6 AWG electrode cable
with lug.
ā¢ Fifteen feet (4.6 meters) of #6 work cable with lugs.
ā¢ Work Clamp
ā¢ Headshield with No. 10 filter
ā¢ Insulated electrode holder and sample electrodes
150 amp capacity.
Undercarriage (K2722-1) - A two-wheeled, hand mov-
able undercarriage is available for field installation.
Rotor Removal Kit (S20925) - A service kit with thru
bolt and impact boltās 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 OutbackĀ®
185 when not in use. Made from attractive red canvas
which is flame retardant, mildew resistant and water
repellent.
OUTBACKĀ® 185
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D-1
D-1
TABLE OF CONTENTS - MAINTENANCE SECTION
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Engine Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Major Component Locationss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
OUTBACKĀ® 185
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D-3
D-3
MAINTENANCE
OIL: Check the oil level after every 5
hours of operation or daily. BE SURE
TO MAINTAIN THE OIL LEVEL.
SAFETY PRECAUTIONS
WARNING
Change the oil the first time after 20 hours of opera-
tion. Then, under normal operating conditions, change
the oil after every 100 hours or once a year, whichev-
er occurs first. If the engine is operated under heavy
load or in high ambient temperatures, change the oil
every 50 hours.
ā¢ Have qualified personnel do all maintenance and
troubleshooting work.
ā¢ Turn the engine off before working inside the
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 Ownerās manual for spe-
cific oil recommendations.
ā¢ Remove guards only when necessary to perform
maintenance and replace them when the mainte-
nance requiring their removal is complete.
ā¢ If guards are missing from the machine, get replace-
ments from a Lincoln Distributor. See the EXPLOD-
ED VIEW AND PARTS LIST at the back of this man-
ual.
FIGURE D.1 - OIL DRAIN AND
REFILL LOCATION
------------------------------------------------------------------------
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-
BACKĀ®185 Keep all equipment safety guards, covers,
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 start-
ing, operating, or repairing this machine.
Do not screw in
dipstick to check oil
FILL to FULL mark on
dipstick - recheck
ROUTINE AND PERIODIC
MAINTENANCE
12 mm
HEX
ENGINE MAINTENANCE
CAUTION
Drain
plug
To prevent the engine from accidentally starting, dis-
connect the spark plug lead before servicing the
engine.
OIL DRAIN
PLUG
Oil drain
Tighten dipstick
firmly before starting
------------------------------------------------------------------------
See the Kohler Ownerās manual for a summary of
maintenance intervals for the engine. Follow either the
hourly or the calendar intervals, whichever come first.
More frequent service may be required, depending on
your specific application and operating conditions. The
Kohler Ownerās manual shows engine maintenance
replacement parts and numbers.
FUEL: At the end of each dayās use, refill
the fuel tank to minimize moisture conden-
sation and dirt contamination in the fuel
line.
AIR CLEANER: With normal operating
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 Ownerās Manual for more information.
OUTBACKĀ® 185
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D-4
D-4
MAINTENANCE
To service the pre-cleaner:
SLIP RINGS
Remove the cover. Carefully remove the foam pre-
cleaner from the filter element.
CAUTION
1. Wash in liquid detergent and water.
2. Squeeze dry in a clean cloth.
3. Saturate in clean engine oil.
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.
4. Squeeze in a clean, absorbent cloth to remove all
excess oil.
Do not attempt to polish slip rings while engine is
running.
Carefully place the pre-cleaner back over the filter ele-
ment and reinstall the air cleaner cover and wing nuts.
-----------------------------------------------------------------------
HARDWARE
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.
Both English and Metric fasteners are used in this
welder.
ENGINE MAINTENANCE PARTS
Kohler CS 12.75
SPARK PLUG SERVICE
Air Filter Element
Air Filter Pre-Cleaner
Spark Plug
63 083 19-S
63 083 17-S
Champion RC 12YC
(Gap .030ā [.76mm])
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.
(Resistor Type)
FIGURE D.2
OPERATIONAL CLEARANCE
CAUTION
Approximately 12-18ā 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.
------------------------------------------------------------------------
ENGINE ADJUSTMENTS
WARNING
OVERSPEED IS HAZARDOUS - The maximum
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.
OUTBACKĀ® 185
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D-6
D-6
NOTES
OUTBACKĀ® 185
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E-1
E-1
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
Engine Starting, Protection and Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2, E-3
Automatic Idle System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
Generating Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5, E-6
FIGURE E.1 BLOCK LOGIC DIAGRAM
CURRENT
120 VAC RECEPTACLES
240 VAC
SENSOR
RECEPTACLE
OIL LEVEL
INDICATOR
CB1
CB2
CB3
CB4
OIL
LEVEL
MODULE
(KOHLER)
REACTOR
OIL LEVEL
SWITCH
AUXIIARY WINDINGS
SLIP
STATOR
RINGS
_
+
CHOKE
+
OUTPUT
RECTIFIER
(2 PHASE)
WELD
WINDINGS
OUTPUT
STUDS
IGNITION
ENGINE
ROTOR
BRUSHES
EXCITER
WINDING
STARTER /
SOLENOID
IDLE
ALTERNATOR
SOLENOID
BOOST
10 AMP
FUSE
WINDING
OFF
AUTO
HIGH
_
+
START
BATTERY
ENGINE
SHUTDOWN
RELAY
OUTPUT
CONTROL
AUTOMATIC
IDLER
OUTPUT
CONTROL CIRCUIT
CIRCUIT
HOUR
METER
FIELD / CONTROL PC BOARD
OUTBACKĀ® 185
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 - ENGINE STARTING, PROTECTION AND BATTERY CHARGING
CURRENT
SENSOR
120 VAC RECEPTACLES
240 VAC
RECEPTACLE
OIL LEVEL
INDICATOR
CB1
CB2
CB3
CB4
OIL
LEVEL
MODULE
(KOHLER)
REACTOR
OIL LEVEL
SWITCH
AUXIIARY WINDINGS
SLIP
STATOR
RINGS
_
+
CHOKE
+
OUTPUT
RECTIFIER
(2 PHASE)
WELD
WINDINGS
OUTPUT
STUDS
IGNITION
ENGINE
ROTOR
BRUSHES
EXCITER
WINDING
STARTER /
SOLENOID
IDLE
ALTERNATOR
SOLENOID
BOOST
10 AMP
FUSE
WINDING
OFF
AUTO
HIGH
_
+
START
BATTERY
ENGINE
SHUTDOWN
RELAY
OUTPUT
CONTROL
AUTOMATIC
IDLER
OUTPUT
CONTROL CIRCUIT
CIRCUIT
HOUR
METER
FIELD / CONTROL PC BOARD
If the battery is too low to properly power the starter
motor, the built-in recoil starter can be used to crank
the engine. (As long as the battery can produce 6 volts
or more, the engine ignition system will remain
enabled.)
ENGINE STARTING, PROTECTION
AND BATTERY CHARGING
ENGINE STARTING
A 12 Volt battery supplies power to the rotary
run/stop/idle switch through a fuse that is located
inside the control box. There is also a lead running
from the fuse to the PC board. This is for battery
charging only.
NOTE: This machine will only start if there is at least 6
volts available to activate the engine ignition system. If
the battery is removed or completely dead, the engine
will not start.
When the switch is placed in the āLow Idleā or āHigh
Idleā position, a relay on the PC board is activated.
This relay activates the engine ignition system by
opening a ground lead from the engine magneto.
ENGINE PROTECTION
The Kohler engine has a built-in oil level sensor that is
connected to an oil level module. If the oil level is low,
the ignition magneto is disabled. This will prevent the
engine from starting, or shut it down. Low oil level will
also cause a warning light on the OutbackĀ®ās control
panel to flicker for a few seconds when cranking the
engine.
When the switch is held in the āStartā position, the
starter motor solenoid is activated, cranking the
engine. After the engine starts, the switch is released
and returns to the āhigh idleā position.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
OUTBACKĀ® 185
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E-3
E-3
THEORY OF OPERATION
FIGURE E.3 - ENGINE STARTING, PROTECTION AND BATTERY CHARGING
CURRENT
SENSOR
120 VAC RECEPTACLES
240 VAC
RECEPTACLE
OIL LEVEL
INDICATOR
CB1
CB2
CB3
CB4
OIL
LEVEL
MODULE
(KOHLER)
REACTOR
OIL LEVEL
SWITCH
AUXIIARY WINDINGS
SLIP
STATOR
RINGS
_
+
CHOKE
+
OUTPUT
RECTIFIER
(2 PHASE)
WELD
WINDINGS
OUTPUT
STUDS
IGNITION
ENGINE
ROTOR
BRUSHES
EXCITER
WINDING
STARTER /
SOLENOID
IDLE
ALTERNATOR
SOLENOID
BOOST
10 AMP
FUSE
WINDING
OFF
AUTO
HIGH
_
+
START
BATTERY
ENGINE
SHUTDOWN
RELAY
OUTPUT
CONTROL
AUTOMATIC
IDLER
OUTPUT
CONTROL CIRCUIT
CIRCUIT
HOUR
METER
FIELD / CONTROL PC BOARD
NOTE: The engine charging system must be function-
al for the OutbackĀ® 185 to produce weld or auxiliary
output.
ENGINE STARTING, PROTECTION
AND BATTERY CHARGING (contin-
ued)
NOTE: The battery must remain connected at all times.
If the battery is disconnected while the machine is run-
ning, unstable voltage from the charging system will
likely cause the PC board electronics to malfunction
and may cause permanent damage to the PC board.
BATTERY CHARGING
The Kohler engine has a built-in battery charging sys-
tem. Output from the charging system is applied to the
PC board where it is stabilized by the battery and then
used to power the board electronics, the generator
flashing system, and the hour meter. The remaining
output exits the PC board, is routed through a fuse
located inside the control box, and applied to the bat-
tery.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
OUTBACKĀ® 185
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E-4
E-4
THEORY OF OPERATION
FIGURE E.4 - AUTOMATIC IDLE SYSTEM
CURRENT
SENSOR
120 VAC RECEPTACLES
240 VAC
RECEPTACLE
OIL LEVEL
INDICATOR
CB1
CB2
CB3
CB4
OIL
LEVEL
MODULE
(KOHLER)
REACTOR
OIL LEVEL
SWITCH
AUXIIARY WINDINGS
SLIP
STATOR
RINGS
_
+
CHOKE
+
OUTPUT
RECTIFIER
(2 PHASE)
WELD
WINDINGS
OUTPUT
STUDS
IGNITION
ENGINE
ROTOR
BRUSHES
EXCITER
WINDING
STARTER /
SOLENOID
IDLE
ALTERNATOR
SOLENOID
BOOST
10 AMP
FUSE
WINDING
OFF
AUTO
HIGH
_
+
START
BATTERY
ENGINE
SHUTDOWN
RELAY
OUTPUT
CONTROL
AUTOMATIC
IDLER
OUTPUT
CONTROL CIRCUIT
CIRCUIT
HOUR
METER
FIELD / CONTROL PC BOARD
Weld and auxiliary current are detected by a toroidal
current sensor that is connected to the PC board.
When sufficient current flows through the sensor; the
PC board detects this and immediately interrupts the
negative (-) connection to the solenoid. The solenoid
is released and the engine RPM increases to the high
setting. When the current flow stops, the PC board will
begin a time delay of about 12 seconds. If the current
flow begins again during this time delay, the solenoid
remains inactive and the engine continues to operate
at high RPM. If no current flow is detected at the end
of the 12 second delay, the negative (-) connection to
the solenoid is restored and the engine will drop to low
idle RPM.
AUTOMATIC IDLE SYSTEM
The OutbackĀ® 185 is equipped with an automatic
engine idle system. A solenoid is used to pull the
engine throttle to a preset low speed position when 12
volts DC is applied. When no voltage is applied, the
solenoid is released allowing the engine governor to
control the RPM.
The āhighā and āautoā positions on the rotary
run/stop/idle switch control the supply of positive (+)
battery voltage to the idle solenoid. When the switch is
in the āhighā position, the solenoid is shut off and the
engine will remain in high idle. When the switch is in
the āautoā position, positive (+) battery voltage is
applied to the solenoid and the negative (-) connection
is controlled by the PC board as described below.
The following explanation assumes that the rotary
switch is in the āautoā position and the engine is oper-
ating at low RPM.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
OUTBACKĀ® 185
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E-5
E-5
THEORY OF OPERATION
FIGURE E.5 - GENERATING POWER
CURRENT
SENSOR
120 VAC RECEPTACLES
240 VAC
RECEPTACLE
OIL LEVEL
INDICATOR
CB1
CB2
CB3
CB4
OIL
LEVEL
MODULE
(KOHLER)
REACTOR
OIL LEVEL
SWITCH
AUXIIARY WINDINGS
SLIP
STATOR
RINGS
_
+
CHOKE
+
OUTPUT
RECTIFIER
(2 PHASE)
WELD
WINDINGS
OUTPUT
STUDS
IGNITION
ENGINE
ROTOR
BRUSHES
EXCITER
WINDING
STARTER /
SOLENOID
IDLE
ALTERNATOR
SOLENOID
BOOST
10 AMP
FUSE
WINDING
OFF
AUTO
HIGH
_
+
START
BATTERY
ENGINE
SHUTDOWN
RELAY
OUTPUT
CONTROL
AUTOMATIC
IDLER
OUTPUT
CONTROL CIRCUIT
CIRCUIT
HOUR
METER
FIELD / CONTROL PC BOARD
āhighā position, all of the windings should be putting out
maximum voltage almost immediately. The rotor field
voltage is now considerably higher than the flashing
voltage that was used to start the generating process.
The āflashingā diode on the control PC board blocks
that higher field voltage from intruding into the 12VDC
battery system.
GENERATING POWER
Flashing
When the engine is running, power from the engine
charging system is stabilized, and then applied to the
rotor brushes through a series of PC board mounted
current limiting resistors and a āflashingā diode.
AC Output
Building Output
The generator is now producing normal AC power from
all four of the windings. These windings consist of two
64 VAC weld windings, a 120/240 VAC auxiliary power
winding, and an 82 VAC excitation winding.
The flashing current produces a weak magnetic field in
the rotor, which is coupled to the now running engine.
This rotating magnetic field begins to generate AC out-
put from all of the stator windings. Output from the
exciter winding is rectified by a diode bridge, filtered by
a capacitor, controlled by circuitry on the PC board,
and fed back into the rotating field winding, making the
magnetic field stronger. This stronger magnetic field
then produces higher voltage from the stator windings,
which feeds back to the rotor, making its magnetic field
even stronger.
This process of strengthening the magnetic field
through feedback from the exciter winding continues to
increase the output of the main generator. If the output
control is set to maximum and the idle switch is in the
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
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E-6
E-6
THEORY OF OPERATION
FIGURE E.6 - GENERATING POWER
CURRENT
SENSOR
120 VAC RECEPTACLES
240 VAC
RECEPTACLE
OIL LEVEL
INDICATOR
CB1
CB2
CB3
CB4
OIL
LEVEL
MODULE
(KOHLER)
REACTOR
OIL LEVEL
SWITCH
AUXIIARY WINDINGS
SLIP
STATOR
RINGS
_
+
CHOKE
+
OUTPUT
RECTIFIER
(2 PHASE)
WELD
WINDINGS
OUTPUT
STUDS
IGNITION
ENGINE
ROTOR
BRUSHES
EXCITER
WINDING
STARTER /
SOLENOID
IDLE
ALTERNATOR
SOLENOID
BOOST
10 AMP
FUSE
WINDING
OFF
AUTO
HIGH
_
+
START
BATTERY
ENGINE
SHUTDOWN
RELAY
OUTPUT
CONTROL
AUTOMATIC
IDLER
OUTPUT
CONTROL CIRCUIT
CIRCUIT
HOUR
METER
FIELD / CONTROL PC BOARD
GENERATING POWER
(continued)
DC Weld Output
Weld Boost:
AC output from the two phase-shifted weld windings
pass through a reactor then to a two-phase bridge rec-
tifier. DC output from the rectifier is then stabilized by
a choke and terminates at two weld output terminals.
The OutbackĀ® 185 is equipped with a weld boost cir-
cuit that improves weld performance. The reactor con-
tains a weld boost winding that produces output rela-
tive to the weld current. In high welding load situations,
the exciter winding will tend to drop off in output while
the boost windingās output tends to increase. The out-
put from this boost winding is routed through a circuit
breaker. It is then rectified and added to the exciter cir-
cuit, resulting in a significant improvement in weld per-
formance.
Weld Output Control
Weld output is controlled by varying the current in the
rotating field winding. This is done through circuitry on
the PC board that detects the position of the output
control potentiometer and then limits the rotor current
accordingly.
NOTE: Because the strength of the rotating field
affects the output of all the windings, auxiliary output
will also drop when the weld output control setting is
decreased.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
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F-1
F-1
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Engine RPM Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Throttle Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-17
Brush and Slip Ring Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-19
Rotor Flashing and Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23
Battery Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-25
Stator Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-27
Rotor Resistance and Ground Test (Static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29
Rotor Resistance and Ground Test (Dynamic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-31
Stator Short Circuit and Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33
Weld Boost System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-35
Case Cover Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-37
Fuel Tank and Enclosure Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-39
Control Box Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-43
Stator Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47
Rotor Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-51
Retest and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-53
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F-2
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.
---------------------------------------------------------------------------------------------------------------------------
Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled āRecommended
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
Course of Actionā lists the most likely com-
procedure listed below.
ponents that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject com-
ponent is either good or bad. If there are a
number of possible components, check the
components in the order listed to eliminate
one possibility at a time until you locate the
cause of your problem.
Step 1. LOCATE PROBLEMź¢(SYMPTOM).
Look under the column labeled āPROBLEM
(SYMPTOMS)ā. This column describes pos-
sible symptoms that the machine may exhib-
it. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems.
All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled āPOSSIBLE
AREAS OF MISADJUSTMENT(S)ā lists the
obvious external possibilities that may con-
tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with-
out removing the case wrap-around cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call 1-888-935-3877.
-----------------------------------------------------------------------------------------------------------------------------------
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F-3
F-3
TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Donāt set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board canāt be
installed immediately, put it back in the static-shield-
ing bag.
WARNING
ELECTRIC SHOCK
can kill.
ā¢
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.
- If the PC board uses protective shorting jumpers,
donāt remove them until installation is complete.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop-
er failure analysis.
CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob-
lems when troubleshooting and replacing PC boards,
please use the following procedure:
4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board
to assure that the PC board is properly
connected.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:
a. If the original problem does not reappear by
substituting the original board, then the PC
board was not the problem. Continue to look
for bad connections in the control wiring
harness, junction blocks, and terminal strips.
PC board can be damaged by static electricity.
b. If the original problem is recreated by the
substitution of the original board, then the PC
board was the problem. Reinstall the
replacement PC board and test the machine.
- Remove your bodyās static
charge before opening the static-
shielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
to
a
equipment frame.
grounded part of the
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
NOTE: Following this procedure and writing on the
warranty report, āINSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,ā will help avoid
denial of legitimate PC board warranty claims.
- If you donāt have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
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F-4
Observe Safety Guidelines detailed in the beginning of this manual.
F-4
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical
damage.
Contact the Lincoln Electric
Service Department at 1-888-935-
3877.
The engine will not crank while 1. Be certain that the battery is 1. Test the fuse located under the
using the electric start function.
properly connected
adequately charged.
and
white cover at the back of the
control box.
2. Try cranking the engine using 2. Test for battery voltage at lead
the recoil starter. If the engine
will still not turn, or the recoil
starter is hard to pull, remove
the spark plug and check for
water or oil in the cylinder. Also
check for high oil level.
210B where it connects to the
starter solenoid, while holding
the switch in the āstartā position.
If voltage is present, the
starter/solenoid assembly is
defective; contact the engine
manufacturer for parts and
service.
3. If the engine cranks normally
while using the recoil starter,
remove the top cover from the 3. If battery voltage is not present,
machine ad check the fuse.
The fuse is located under the
white cover of the back of the
control box.
check the engine switch, and all
connectors and wires
connecting the fuse, switch and
starter solenoid. See the wiring
diagram.
1. Check for battery voltage at the
PC board pin J3-10. (lead #211)
If voltage is not resent, the
engine switch or wire #211 may
be defective.
1. If using the recoil starter, be
sure the engine switch is in the
āhighā or āautoā position.
Engine will not start. The starter
motor will crank the engine
normally.
2. Check that the fuel valve is
open, and that there is
sufficient, fresh gasoline in the
tank.
2. Check PC board ground at pin
J1-2. (lead GND-G)
3. Place the engine switch in the
āstopā position, unplug engine to
welder harness connector
(P4/J4) located inside the
control box at the bottom left.
CAUTION: Disconnecting
this plug disables the normal
engine shut down function of
the engine switch.
3. Be certain that the battery is
properly
connected
and
adequately charged, even if
using the recoil starter.
4. Check the engine oil level.
5. Check or replace the fuel filter.
6. Check or replace air filter.
7. Check the spark plug. Clean or
replace if necessary.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
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F-5
Observe Safety Guidelines detailed in the beginning of this manual.
F-5
TROUBLESHOOTING AND REPAIR
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.
Reconnect P4/J4 to shut the
engine down.
Attempt to start the engine
using the recoil starter; if the
engine starts, check lead #212
for faulty insulation. If lead
#212 is good, replace the PC
board.
If the engine fails to start, have
the engine and oil level system
checked by a qualified engine
service technician.
1. Place the engine switch in the
āstopā position and check for
battery voltage at the PC board
pin J3-10. (lead #211) If
voltage is present, the switch is
defective.
The engine will not shut down.
2. Locate and ground the
brown/white lead from the
engine ignition magneto. If the
engine still will not shut down,
the engine ignition magneto
may be defective. Contact a
qualified engine technician.
3. If the engine shuts down when
the brown/white lead is
grounded, check wiring and
connections at leads #212,
GND-I, GND-J, and the brown
leads between connector J4/P4
and the engine ignition
magneto. If these leads and
connections are good, replace
the PC board.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
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F-6
Observe Safety Guidelines detailed in the beginning of this manual.
F-6
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
1. Check the idle solenoid and
engine carburetor linkage for
damage, excessive dirt, or
binding. If possible, perform
The engine runs erratically or 1. Check that the fuel valve is fully
stops running.
open, and that there is
sufficient, fresh gasoline in the
tank.
2. The choke may be engaged.
Be sure the choke handle is
pushed in completely after the
engine has begun to warm up.
2. Place the engine switch in the
āstopā position, unplug engine
to welder harness connector
(P4/J4) located inside the
control box at the bottom left.
CAUTION: Disconnecting this
plug disables the normal engine
shut down function of the
engine switch. Reconnect
P4/J4 to shut the engine down.
3. Be certain that the battery is
properly
connected
and
adequately charged, even if
using the recoil starter.
4. Check the engine oil level.
5. Check or replace the fuel filter.
6. Check or replace air filter.
3. Attempt to start the engine
using the recoil starter.
7. Check spark plug; clean or
replace if necessary.
4. If the problem persists check for
faulty insulation at the brown
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.
and
brown/white
wires
connecting P4/J4 to the engine
magneto. If the insulation is
good, contact a qualified engine
repair technician.
5. If the engine runs normally with
P4/J4 disconnected, check for
battery voltage between J3-10
(+) and J1-2 (-). If the voltage
is low or erratic, check
conductors and connections at
GND-G, lead #211, lead 209A,
and lead 230. Check the fuse,
fuse holder, and the engine
switch. Replace or repair any
defective leads or components.
9.Perform
any
additional
maintenance suggested in the
engine operatorās manual.
6. If the voltage between J3-10 (+)
and J1-2 (-) is normal, check for
defective insulation on lead
212. If insulation is good,
replace PC board.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
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F-7
Observe Safety Guidelines detailed in the beginning of this manual.
F-7
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
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
and auxiliary outputs are normal.
in the āAutoā position.
improperly adjusted. Perform
2. Check that the engine choke is
fully open.
2. With the engine running, place
the engine switch in the āAutoā
position. Check for battery
voltage at the idle solenoid,
lead 213B. if battery voltage is
not present, check engine
switch, connector P4/J4, and
leads 213A and 213B.
3. There may be a load on the
weld or auxiliary output.
Disconnect all cables and cords.
3. If battery voltage was detected
in step #2 above, check
connector P4/J4, leads 215
and 215A.
4. Check for AC voltage at leads
260 (J2-3) and 261 (J2-4).
With no load on either the weld
or auxiliary output, the meter
should read about 26 mV. If
the voltage is significantly
higher than this, the toroidal
current transformer may be
faulty, or improperly wired.
This may also indicate a load
on machine input or faulty
internal components drawing
current.
5. If the above readings are
normal, replace the PC board.
Low idle ROM may be set too low.
Perform the engine RPM
Engine idles own but will not stay
at low idle.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
OUTBACKĀ® 185
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F-8
Observe Safety Guidelines detailed in the beginning of this manual.
F-8
TROUBLESHOOTING AND REPAIR
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. Unplug P4/J4 connector and
when a welding or auxiliary load
is applied. Engine idles up
normally and outputs are normal
when the engine switch is placed
in the āhighā position.
check cables, connectors, work
clamp and electrode holder.
Check that work clamp is
making a good connection to
the work piece.
measure the idle solenoid
resistance between leads
213B and 215A. it should
measure about 15 ohms.
Measure the resistance from
lead 213B or lead 215A to
chassis ground. Resistance
should be very high; 500,000
(500K) ohms or higher.
Replace the solenoid if the
resistance is significantly
different.
2. Load too low to activate the idle
circuit. Plug in a device that
applies a load of 100 watts or
more.
NOTE: Some tools and devices
check for āgoodā power before
fully turning on. These devices
will require the machine to be
placed in the āhighā position
before they will function.
2. Reconnect P4/J4 and start the
machine placing the engine
switch in the highā position.
Plug in a 100-watt light bulb.
Check for AC voltage at leads
260 (J2-3) and 261 (J2-4). The
meter should read about 1.2
volts. If voltage is significantly
lower, replace the toroidal
current transformer.
3. If the above readings are
normal, replace the PC board.
1. The brushes and slip rings may
be worn or faulty. Perform the
brush and slip ring service
procedure.
No weld or auxiliary output ā 1. Make sure there is no load on
Engine runs normally.
the machine. Disconnect all
cables and cords from the weld
output terminals and the
auxiliary receptacles. Check for
DC open circuit voltage (OCV)
(About 70 to 80 volts) at the
weld output terminals and check
for AC auxiliary voltage at the
120 and 240 VAC receptacles.
2. With the engine running, check
for battery voltage at the PC
board, J3-9 (lead #208A). If
voltage is not present, check
conductors and connection at
leads 208A, 208, and the
engine wiring leading to the
engine charging system. If the
connections are good, the
battery charging system may
be faulty. Contact a qualified
engine repair technician.
2. Check that circuit breakers are
not tripped.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
OUTBACKĀ® 185
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F-9
Observe Safety Guidelines detailed in the beginning of this manual.
F-9
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
(Continued)
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.
4. If voltage is present at J3-8,
check for battery voltage at J1-
9 (lead #224). If voltage is not
present, check leads 224 and
224A. Check the positive
terminal connections at the
hour meter.
5. Check that the PC board is
properly grounded, pin J1-2
(lead GND-G).
6. Perform the rotor flashing,
7. Perform the stator resistance
1. Check
weld
cables,
There is no weld output, or weld
voltage drops dramatically when
trying to strike an arc. The
115/230 VAC auxiliary output is
1. Check for loose or damaged
connections between the
output terminals, the choke,
the rectifier, the rector, and the
stator. See wiring diagram.
connections, work clamps, and
electrode holder.
2. With engine running at high
idle, and output control set to
maximum, check the DC
voltage at the weld output
terminals. It should measure
70 to 80 Volts RMS.
normal;
normally.
engine
operates
2. With engine running at high
idle, and output control set to
maximum, check for about 63
VAC from each of the two
stator weld windings (W1 to
W2) and (W3 to W4). See
wiring diagram. If voltage is
not present for either test, the
stator is probably defective.
3. With the engine still running,
check for about 63 VAC at
W1A to W2 and from W3A to
W4. If voltage is not present
for either test, the reactor may
be defective.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
OUTBACKĀ® 185
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F-10
Observe Safety Guidelines detailed in the beginning of this manual.
F-10
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
(Continued)
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.
5. If the is voltage at the rectifier
output, but not at the weld
terminals, the choke may be
open.
1. Check for AC voltage at the
back of the receptacles. If
voltage is present at the back
of the receptacles but the
receptacles still will not
No 115/230 VAC auxiliary output ā 1. Check for faulty extension
Weld output is normal and engine
operates normally.
cords, tools, lights, etc. Plug in
a known working device.
2. Check for tripped circuit
breakers.
function,
receptacle.
replace
the
3. If the OutbackĀ® has optional
GFCI receptacles, try resetting
them.
2. Check for 120 VAC from lead
#5 to leads #3 and #6 at the
circuit breakers. See wiring
NOTE: Engine must be running at
high idle RPM or the GFCI
receptacles will not reset.
diagram.
If 120 VAC is
present, one or more circuit
breakers may be defective.
3. If AC voltage is not detected in
step 2 above, check leads
between the test points and the
stator winding. If the leads are
good, the stator is likely
defective.
1. The output control may be set
too low.
Low weld and auxiliary output,
the engine operates normally.
2. The brushes and slip rings may
be worn or faulty. Perform the
2. Engine RPM may be low.
3. The battery may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
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F-11
Observe Safety Guidelines detailed in the beginning of this manual.
F-11
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
performance is poor. Engine
operates normally and auxiliary
output is normal.
may have tripped. This circuit
breaker is a small button on the
bottom of the control box, not
far from the positive weld output
terminal.
2. The brushes and slip rings
may be worn or faulty. Perform
2. Check the weld cables,
electrode holder, and work
clamp. Try welding with a
known good set of short,
adequately sized cables.
3. The battery may be low or
defective.
4. The welding electrode may be
wet or contaminated. Try using
a fresh dry welding electrode.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
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F-12
F-12
NOTES
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F-13
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
Test will determine whether the engine is operating at the correct speed (RPM) during
both HIGH and LOW idle conditions.
MATERIALS NEEDED
Miscellaneous hand tools and metric wrench set
High visibility marker
Strobe-tach, frequency counter, or vibratach
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F-14
F-14
TROUBLESHOOTING AND REPAIR
ENGINE RPM ADJUSTMENT PROCEDURE (continued)
FIGURE F.1 ā STROBE-TACH METHOD
FAN BLADE
STROBE-TACH MARK
PROCEDURE
Strobe-Tach Method
7. Move the idle switch to the āAUTO IDLEā posi-
tion and wait for the idle solenoid to energize.
The engine RPM should drop and stabilize at
the low idle RPM.
1. Turn the engine off.
2. Place a highly visible mark on a component that
rotates while the engine is running. The rotor-
cooling fan is a good place for this mark. See
Figure F.1.
8. Synchronize the strobe-tach to read the low idle
RPM.
3. Connect the strobe-tach according to the man-
ufacturerās instructions.
9. The tach should read between 2250 and 2500
RPM.
4. Start the engine and place the idle switch in the
āHIGH IDLEā position. Make sure that there is
no load on the machine.
10. If either of the readings is incorrect, proceed to
section.
5. Direct the strobe-tach light at the mark and syn-
chronize the strobe-tach.
6. The tach should read between 3700 and 3800
RPM.
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F-15
F-15
TROUBLESHOOTING AND REPAIR
ENGINE RPM ADJUSTMENT PROCEDURE (continued)
FIGURE F.2 ā FREQUENCY COUNTER METHOD
Solenoid & Fuel
Pump Bracket
Engine
Electric Fuel Pump
(codes 10926 &11121 only)
Engine Speed
Control Lever
High Idle
Screw &
Jam Nut
Swivel
Fitting
Low Idle
Jam Nuts
MOVING ENGINE
SPEED CONTROL
LEVER
Rubber
Boot
Solenoid
DECREASE
(RPM)
INCREASE
(RPM)
Frequency Counter Method
4. Move the idle switch to the āAUTO IDLEā posi-
tion and wait for the idle solenoid to energize.
The engine RPM should drop and stabilize at
the low idle RPM.
NOTE: A dedicated frequency counter can be
used for this test, but many high quality
digital multimeters also have this function,
and can be easily utilized. See the manu-
facturerās instructions for your frequency
counter or multimeter.
5. The frequency should read between 47.5 and
41.6 Hz.
1. Set your frequency counter per the meter man-
ufacturerās instructions and plug it into one of
the 120VAC auxiliary receptacles.
6. If either of the readings is incorrect, proceed to
this section.
2. Start the engine and place the idle switch in the
āHIGH IDLEā position. Make sure that there is
no load on this machine.
NOTE: For the OutbackĀ® 185, and any other
Lincoln Electric 3600 RPM (2 Pole)
machine, engine RPM can be determined
by multiplying the frequency, in Hz. by 60.
(Example: 60 Hz. x 60 = 3600 RPM).
3. The frequency should read between 61.6 and
63.3 Hz.
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F-16
F-16
TROUBLESHOOTING AND REPAIR
ENGINE RPM ADJUSTMENT PROCEDURE (continued)
FIGURE F.3 ā VIBRATACH METHOD
HIGH IDLE ADJUSTMENT
LOW IDLE ADJUSTMENT
TOP VIEW OF ENGINE
Vibratach Method
4. Move the idle switch to the āAUTO IDLEā posi-
tion and wait for the idle solenoid to energize,
and the engine RPM to drop and stabilize at the
low idle RPM.
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.
5. Position and adjust the Vibratach; it should read
between 2250 and 2500 RPM.
1. Read and understand the manufacturerās
instructions for the Vibratach.
6. If either of the readings is incorrect, proceed to
this section.
2. Start the engine and place the idle switch in the
āHIGH IDLEā position. Make sure there is no
load on the machine.
3. Position and adjust the Vibratach; is should
read between 3700 and 3800 RPM.
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F-17
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the adjustment of the throttle.
MATERIALS NEEDED
Flathead Screw
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F-18
F-18
TROUBLESHOOTING AND REPAIR
THROTTLE ADJUSTMENT PROCEDURE (continued)
FIGURE F.4 ā HIGH AND LOW IDLE ADJUSTMENT
HIGH IDLE ADJUSTMENT
LOW IDLE ADJUSTMENT
TOP VIEW OF ENGINE
PROCEDURE
Low Idle Adjustment
High Idle Adjustment
1. With engine running and no load applied to the
machine, place the engine switch in the āAUTO
IDLEā position. Wait for the idle solenoid to
energize and the engine speed to drop and sta-
bilize at low idle RPM.
Check that the linkage attaching the solenoid to the
engine speed control lever is in good condition and
moves freely.
1. Start the engine and place the engine switch in
the āHIGH IDLEā position. The solenoid should
be de-energized. Be certain that there is no
load on the machine.
2. If the low idle RPM requires adjustment, turn
the low idle adjustment screw. See Figure F.4.
The low idle RPM should be between 2250 and
2500 RPM.
2. If the high idle RPM requires adjustment, using
flathead screw turn the high idle adjustment
screw. See Figure F.4. Turning the screw
clockwise will increase RPM and turning it
counterclockwise will decrease the RPM.
Engine high idle RPM should be between 3700
and 3800 RPM.
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F-19
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
PROCEDURE DESCRIPTION
This procedure provides guidance in testing and maintaining the brush and slip ring sys-
tem.
MATERIALS NEEDED
500 or 600 grit emery cloth
220 or 320 grit commutator stone (Optional)
Needlenose Pliers
1/4ā Nut Driver
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F-20
F-20
TROUBLESHOOTING AND REPAIR
BRUSH AND SLIP RING SERVICE PROCEDURE (continued)
FIGURE F.5 ā BRUSH HOLDER ASSEMBLY LOCATION
BRUSH HOLDER ASSEMBLY
SCREWS (2)
LOCKING TABS
COVER
GENERATOR END BRACKET
PROCEDURE
6. The brushes should be of sufficient length and
have adequate spring tension. Generally, the
brushes should be replaced if either brush has
less than 1/4ā remaining before it reaches the
end of its travel. Spring tension should be suf-
ficient to hold the brushes firmly against the slip
rings.
1. Remove the brush cover from the end of the
generator.
2. Pry outward at the top of the plastic brush cover
while depressing the two locking tabs at the
sides of the cover. See Figure F.5.
3. Remove the brush and brush holder assembly.
7. The brushes should be removed from the brush
holder and be examined. The terminals should
be clean. The shunt, (braided lead connecting
the carbon brush to the terminal) should be in
good condition and firmly connected to the car-
bon brush and to the connection terminal.
4. Use needle-nose pliers to remove the leads
from the brush terminals, and then use the 1/4ā
nut driver to remove the two screws holding the
brush holder in place. The brush holder assem-
bly can now be pulled straight out from the end
of the generator toward the front of the
machine.
8. If the slip rings are discolored, display evidence
of excessive sparking, or the brushes have
worn prematurely; these may be signs of a
5. Examine brushes and slip rings. The slip rings,
brush holder, and brushes should be clean and
free from oil or grease. The brushes should be
making good, continuous contact with the slip
rings.
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F-21
F-21
TROUBLESHOOTING AND REPAIR
BRUSH AND SLIP RING SERVICE PROCEDURE (continued)
FIGURE F.6 ā BRUSH REMOVAL AND REPLACEMENT
CABLE TIE
BRUSHES
9. Check for evidence of sticking brushes.
2. Use low-pressure compressed air to thoroughly
blow the carbon, commutator stone and sand-
paper dust from the machine before operating.
Sticking brushes will normally result in the slip
rings being pitted and discolored from exces-
sive arcing. Another sign of sticking brushes is
instability or loss of both weld and auxiliary out-
put, but the machine may also begin to work
properly for a short time after being jarred or
moved.
3. To install the brush holder assembly, push the
brushes into the brush holder assembly and
place a plastic cable tie through the holes pro-
vided. See Figure F.6.
4. Slide the brush holder assembly back into the
generator and secure with the two screws
removed earlier. Reattach the leads and
remove the cable tie. Replace the plastic gen-
erator cover.
10. If there is any evidence that the brushes may
have been sticking in the brush holders, a new
brush holder and brush assembly should be
installed.
Cleaning Slip Rings
1. In the event that the slip rings have become
dirty, discolored or mildly pitted, it will become
necessary to clean them using very fine 500 or
600 grit emery cloth or a 220 or 320 grit com-
mutator stone.
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F-22
F-22
NOTES
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F-23
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if correct voltage is being applied to the rotor slip rings.
MATERIALS NEEDED
Misc. hand tools
Multimeter
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F-24
F-24
TROUBLESHOOTING AND REPAIR
ROTOR FLASHING AND VOLTAGE TEST (continued)
FIGURE F.7 ā BRUSH AND SLIP RING LOCATIONS
SLIP RINGS
BRUSHES
+
-
PROCEDURE
9. Check for battery voltage at lead 224 (J1-9).
1. Be certain the battery is fully charged and the
battery charging system is functioning normally.
Check that the PC board is properly grounded
at lead GND-G (J1-2). If the board is getting
battery voltage and is properly grounded,
replace the board.
2. Ensure that there is no load on either the weld
or auxiliary outputs.
3. Set the output control to maximum.
10. If the voltage reading is about 3 to 5 volts DC,
check for AC voltage between Lead #7
(Terminal B2) and Lead #9 (Terminal B1). If
the voltage is about the same or higher than
the voltage reading of the brush leads, replace
the board.
4. Remove the plastic brush cover from the end of
5. Attach voltmeter leads to the brush terminals.
(The positive terminal is closest to the genera-
tor winding)
11. If the AC voltage between leads #7 and #9 is
significantly lower than the DC voltage on the
6. Start the engine and place the engine switch in
the āHIGHā position.
7. The voltmeter should read about 50 VDC.
8. If the voltage reading is zero or near zero, per-
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F-25
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the battery charging system is functioning properly.
MATERIALS NEEDED
Misc. hand tools
Multimeter
Jumper lead with a 10-amp inline fuse or circuit breaker
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F-26
F-26
TROUBLESHOOTING AND REPAIR
BATTERY CHARGING SYSTEM TEST (continued)
FIGURE F.8 ā CHARGING SYSTEM
BATTERY
PROCEDURE
WARNING
4. Disconnect lead #208 from the engine alterna-
DO NOT REMOVE BATTERY
CABLE WHILE MACHINE IS RUN-
NING, OR ATTEMPT TO OPERATE
THE ENGINE WITHOUT A BAT-
TERY CONNECTED. Serious dam-
age to the PC board may result.
tor and place a fused jumper lead between the
alternator and the positive battery terminal.
See Figure F.8. See wiring diagram.
5. Start the engine and check voltage at the bat-
tery. If the DC voltage is now 13.5 to 14.5,
check leads 208, 208A, and lead 209. If these
leads and connections are good, replace the
board.
1. Be sure the battery is fully charged, in good
condition and is securely connected.
2. Start the engine and test the voltage at the bat-
tery terminals. The meter should read between
13.5 and 14.5 volts DC.
6. If the voltage is still low, or if the inline fuse
blows, the engine charging system is most like-
ly faulty. Contact a qualified engine repair tech-
nician.
3. If the voltage is low, shut off the engine.
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F-27
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test determines if the stator is producing the correct voltage from each of the wind-
ings. This test should be performed if rotor voltage is normal but one or more of the out-
put voltage readings are incorrect.
MATERIALS NEEDED
Miscellaneous hand tools
Wiring diagram
Multimeter
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F-28
F-28
TROUBLESHOOTING AND REPAIR
STATOR VOLTAGE TEST (continued)
FIGURE F.9 ā HIGH AND LOW IDLE ADJUSTMENT
HIGH IDLE ADJUSTMENT
LOW IDLE ADJUSTMENT
TOP VIEW OF ENGINE
PROCEDURE
5. If the voltage is not present or is significantly dif-
ferent from expected readings, check the wiring
between test points and the stator winding. See
wiring diagram. If the wiring is in good condi-
tion, the stator is defective.
1. Verify that the engine RPM is normal. See the
2. Start the machine and place the idle switch in
the high position. See Figure F.9.
3. Check for AC voltage between the neutral stud
on the control panel bottom and the #3 lead
connection at the CB1 circuit breaker. Also
check the voltage between the neutral stud and
the #6 lead connection at the CB1 circuit break-
er. Voltage should read between 115 and 130*
volts. See wiring diagram.
*Voltage shown is for a stator that is at normal full
load temperature. Readings will likely be slightly
higher if machine is cold.
4. Check for AC voltage between leads W1 and
W2. See Wiring Diagram. Voltage reading
should be about 64*VAC. Also check for AC
voltage between leads W3 and W4. Voltage
reading should be about 62*VAC. See wiring
digram.
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F-29
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the rotor winding is open, shorted or grounded.
MATERIALS NEEDED
Miscellaneous hand tools
Ohmmeter (analog type meter required for dynamic resistance test)
Wiring Diagram
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F-30
F-30
TROUBLESHOOTING AND REPAIR
ROTOR RESISTANCE AND GROUND TEST (STATIC) (continued)
FIGURE F.10 ā ROTOR RESISTANCE
SLIP RINGS
BRUSHES
+
PROCEDURE
6. Measure the resistance to ground. Place one
meter probe on either of the slip rings. Place
the other probe on any good, unpainted chassis
ground. The resistance should be very high, at
least 500,000 (500k) ohms.
1. Turn the engine off.
2. Remove the plastic cover from the end of the
3. Using needle-nose pliers, remove the leads
from the brush terminals. This will electrically
isolate the rotor windings.
7. If the test does not meet the resistance specifi-
cations, then the rotor may be faulty and should
be replaced.
4. Remove the brush and brush holder assembly.
8. If this test meets resistance specifications, con-
tinue testing using the Dynamic Rotor
5. Using the ohmmeter, check the rotor winding
resistance across the slip rings. Normal resis-
tance is approximately 9* ohms, at 77Ā°F.
(25Ā°C.)
*Voltage shown is for a stator that is at normal full
load temperature. Readings will likely be slightly
higher if machine is cold.
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F-31
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will aid the technician in checking for faults in the rotor winding.
MATERIALS NEEDED
Analog Ohmmeter
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F-32
F-32
TROUBLESHOOTING AND REPAIR
ROTOR RESISTANCE AND GROUND TEST (DYNAMIC) (continued)
FIGURE F.11 ā BRUSH AND SLIP RING LOCATIONS
SLIP RINGS
BRUSHES
+
5. Start the engine and run it at high idle speed.
The resistance should read approximately 9*
ohms at 77Ā°F. (25Ā°C.)
PROCEDURE
NOTE: This test is performed using a good quali-
ty analog type ohmmeter. Many digital
meters will not provide stable or accurate
resistance readings while the rotor is spin-
ning.
6. Shut off engine, and move one of the ohmmeter
leads to a good clean chassis ground connec-
tion.
7. Restart the engine and run it at high idle speed.
The resistance should be very high, at least
500,000 (500k) ohms.
1. This test requires that the brushes and slip rings
are clean, in good condition, and are properly
seated.
8. If the resistance readings differ significantly
from the values indicated, re-check the brushes
and the brush spring tension. If the brushes
and slip rings are good, replace the rotor.
brush assembly.
3. Insulate the lead wires that had been discon-
nected from the brushes during the static rotor
resistance test.
9. Re-attach the brush leads and install the brush
cover.
*NOTE: The resistance of the copper windings will
change the temperature. Higher temper-
atures will produce higher resistance, and
lower temperatures will produce lower
resistance.
4. Securely attach the ohmmeter leads to the
brush terminals. Use clips or terminals to
attach the leads BEFORE starting the engine.
See Figure F.11.
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F-33
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if there are undesirable electrical connections between the stator
windings and chassis ground, or between individual windings within the stator. This test
should be performed if flashing voltage is present at the rotor slip rings, but the voltage
output on leads #7 and #9 is too low.
MATERIALS NEEDED
Miscellaneous hand tools
Ohmmeter
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F-34
F-34
TROUBLESHOOTING AND REPAIR
STATOR SHORT CIRCUIT AND GROUND TEST (continued)
7. If the stator is not grounded, check for short cir-
cuit connections between the windings that
should be isolated from each other.
PROCEDURE
2. Disconnect anything that may be connected to
the auxiliary receptacles or the weld output ter-
minals.
8. Using an ohmmeter; check the resistance
between the following points. Resistance
should red very high, 500,000 (500k) ohms min-
imum.
3. Disconnect and isolate GND-C lead from the
ground stud on the control panel front. See
wiring diagram.
a) The #5 lead that had been disconnected
from the neutral stud, and either lead #7 or
lead #9. (This checks for a connection
between the auxiliary power winding and
the excited winding.)
4. Disconnect and isolate lead #5 from the neutral
stud on the control panel bottom. See wiring
diagram.
b) The #5 lead that had been disconnected
from the neutral stud, and lead W1 or W2.
(This checks for a connection between the
wire auxiliary power winding and one of
the weld windings.)
5. Disconnect the #7 and #9 leads from the PC
board.
6. Using an ohmmeter, check the resistance
between chassis ground and each of the fol-
lowing points; resistance should read very high:
500,000 (500k) ohms minimum.
c) The #5 lead that has been disconnected from
the neutral stud, and lead W3 or W4. (This
checks for a connection between the auxiliary
power winding and the other weld winding.)
a) The #5 lead that had been disconnected from
the neutral stud. (This tests for a grounded
auxiliary winding.)
d) Lead #7 and lead W1 or W2. (This checks
for a connection between the exciter wind-
ing and one of the weld windings.)
b) The #7 or #9 lead. (This tests for a ground-
ed exciter winding.)
c) W1 or W2 lead. (This tests for a grounded
weld winding.)
e) Lead #7 and lead W3 or W4. (This checks
for a connection between the exciter wind-
ing and the other weld winding.)
d) W3 or W4 lead. (This tests for a grounded
weld winding.)
If any of the above readings is less than 500,000
(500k) ohms, check for damaged, contaminated, or
shorted wiring, or defective components connected
to the stator windings. If necessary, disconnect
and isolate leads as close to the stator winding as
possible. See Wiring Diagram. If the low resis-
tance is determined to be between the windings
within the stator, the stator is defective and should
be replaced.
If any of these readings are less than 500,000
(500k) ohms, check for grounded components or
wiring that remain connected to the stator, such as
circuit breakers, receptacles, output rectifier, reac-
tor, etc. See Wiring Diagram. If necessary, dis-
connect and isolate the stator leads as close to the
stator winding as possible. If the low resistance to
ground is determined to be in the stator windings,
the stator is defective and should be replaced.
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F-35
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test checks the functionality of the weld boost system. This test should be done if
the weld terminal open circuit voltage and engine RPM are normal, but the machine weld
output is low.
MATERIALS NEEDED
Resistive load bank
Misc. hand tools
Multimeter
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F-36
F-36
TROUBLESHOOTING AND REPAIR
WELD BOOST SYSTEM TEST (continued)
FIGURE F.12 ā HIGH AND LOW IDLE ADJUSTMENT
HIGH IDLE ADJUSTMENT
LOW IDLE ADJUSTMENT
TOP VIEW OF ENGINE
PROCEDURE
10. Start the engine and apply a load of about 80
to 100 Amps.
1. Check that the CB4 circuit breaker is not tripped.
2. Check that the battery is fully charged and in
good condition.
11. Check for AC voltage between leads 13 and 14
at the PC board. See wiring diagram.
3. Set the output dial to the Maximum position.
12. If voltage is present, rotate the output control
knob and observe the voltage between leads
13 and 14. The voltage should rise and fall as
the output control is moved.
4. Start the engine and place the engine switch in
the High idle position.
5. Verify that the engine RPM is correct. See the
13. If the voltage at leads 13 and 14 is responding
as described above, the PC board is probably
defective.
6. Turn on the load bank and adjust to get a 165 to
190 Amp load.
14. If no significant voltage is detected at leads 13
and 14, and if the voltage does not respond to
changes to the output control knob setting,
check for a defective CB4 circuit breaker.
Check for poor connections or damaged wires
at leads 13, 13A and 14. If the breaker and
wires are good, the reactor is likely defective.
7. Check engine RPM, it should not fall below 3300
RPM.
8. Read the DC voltage at the output terminals. If
the voltage is between 21 and 27, the boost sys-
tem is functioning normally.
9. If the weld terminal voltage is low. Shut off the
engine and perform the Case Cover Removal
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F-37
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the case sheet
metal covers.
MATERIALS NEEDED
3/8ā Wrench
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F-38
F-38
TROUBLESHOOTING AND REPAIR
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.13 ā CASE COVER REMOVAL
CASE SCREWS
CASE SCREWS
PROCEDURE
1. Using a 3/8ā wrench, remove all screws from
the top of the red sheet metal cover.
2. Lift the top cover off of the machine
3. To replace the cover, reverse the above proce-
dure.
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F-39
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. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the fuel tank
enclosure.
MATERIALS NEEDED
Approved gasoline container and pump
7/16ā Wrench
Rags
Pliers
3/8ā Wrench
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F-40
F-40
TROUBLESHOOTING AND REPAIR
FUEL TANK AND ENCLOSURE
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.14 ā FUEL TANK REMOVAL
FUEL TANK
3/8ā SCREWS
3/8ā SCREWS
FUEL TANK ENCLOSURE
PROCEDURE
WARNING
5. Using pliers, remove fuel line clamp located on
gasoline valve.
Because gasoline is highly
flammable, the following
6. Carefully remove the fuel line from the gasoline
valve.
procedures should be done in
a well-ventilated area; far
away from flame, sparks, or
any other sources of ignition.
7. Flex the end of the sheet steel fuel tank enclo-
sure out slightly and lift the tank out of the
machine.
8. If access to the top of the engine is required,
using the 3/8ā wrench, remove the five screws
holding the bottom of the fuel tank enclosure
and lift it out of the machine.
2. Close gasoline valve. āRed Leverā located on
bottom of gas tank.
3. Using a 7/16ā wrench, disconnect the negative
placement; label and disconnect for reassem-
bly.
4. Pump gasoline into an approved gasoline con-
tainer.
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F-42
F-42
NOTES
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F-43
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the control box.
MATERIALS NEEDED
Cable Ties
Wire Marking Supplies
Wiring Diagram
Phillips Screwdriver
3/8ā Wrench
7/16ā Wrench
Needle Nose Pliers
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F-44
F-44
TROUBLESHOOTING AND REPAIR
CONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.16 ā CONTROL BOX REMOVAL
FUEL TANK
CONTROL BOX
END PANEL
3/8ā SCREWS
PROCEDURE
9. Using the wiring diagram, identify all of the
wires, wire splices, and plugs that connect con-
trol box components to the engine and genera-
tor. If any wire or connector is not clearly
marked, mark them so they can be properly
reconnected. It is also helpful to make notes as
needed.
2. Using the 7/16ā wrench, loosen battery mount-
ing bracket. See Figure F.16.
3. Remove the battery.
10. Cut cable ties as needed and disconnect
these wires.
5. Disconnect the spark plug wire to prevent acci-
dental starting of the engine.
11. Remove any remaining 3/8ā screws from left
side of the control box and gently lift the con-
trol box off the generator assembly.
6. Replace three of the screws that had been
removed when the fuel tank enclosure bottom
was removed. These screws are used to tem-
porarily secure the end panel on the control
box.
12. Reverse the above procedure to reassemble.
13. Replace any cable ties removed during disas-
sembly.
7. Using Phillips screwdriver, remove choke cable
mounting.
8. Using pliers, remove choke cable from engine.
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F-45
F-45
TROUBLESHOOTING AND REPAIR
CONTROL BOX REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.17 ā BATTERY LOCATION
MOUNTING BRACKET
BATTERY
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F-46
F-46
NOTES
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F-47
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the stator.
MATERIALS NEEDED
1/2ā Wrench
7/16ā Wrench
Hoist
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F-48
F-48
TROUBLESHOOTING AND REPAIR
STATOR REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.18 ā STATOR REMOVAL
HAMMER TAPPING
POINTS
TOLERANCE RING
BRUSH ASSEMBLY
CAST END BRACKET
BEARING BRACKET END COVER
PROCEDURE
6. Using a 7/16ā wrench, remove the four bolts
connecting the cast stator brackets. Note the
precise position of all hardware components
and washers. Using a plastic hammer, gently
and evenly tap outward on the end cast brack-
et. See Figure F.18.
3. Label and disconnect any wiring connecting the
engine/generator assembly to the tubular
frame. Remove cable ties and flexible plastic
conduit as needed. See wiring diagram.
The stator frame assembly can now be carefully
removed.
4. Using the 1/2ā wrench, remove the nuts secur-
ing the generator and engine to the rubber
mounts. Note ground lead and washer place-
IMPORTANT: Handle and store the stator careful-
ly to avoid damage to the windings.
5. Use a hoist or get a helper and lift the engine
and generator assembly out of the tubular steel
frame. Place the engine and generator assem-
bly on a strong, solid work surface.
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F-49
F-49
TROUBLESHOOTING AND REPAIR
STATOR REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.19 ā NUTS & RUBBER ENGINE MOUNTS
RUBBER ENGINE MOUNT
āOTHER ENGINE MOUNTS NOT
VISIBLE FROM THIS ANGLEā
Installing the stator assembly:
1. If the rotor has been removed, it must be
replaced before installation of the stator assem-
6. Adjust the stator and brackets as needed and
install the stator through bolts, placing the hard-
ware components the same as they were
before removal.
Important! Always use a new tolerance ring
when reassembling the brush-end end bracket.
It is also highly recommended that the bearing
be replaced.
7. Place the engine and generator assembly into
the tubular frame of the machine and loosely
install the rubber mount fasteners.
2. Examine the cast end brackets and the stator
assembly. Be sure the locating points are free
of varnish and any debris.
8. Make final adjustments to the position of the
brackets and stator. The stator lead bundle
should exit the end bracket at the center of the
hole provided. Evenly tighten the stator through
bolts to a torque of 4.5 to 5.5 ft-lbs.
3. Place the stator in the cast end bracket.
4. Clean the bearing recess in the brush end
bracket and install a new tolerance ring.
9. Tighten the mounting fasteners.
5. Place the brush end bracket over the stator.
Use a plastic or rubber hammer to tap the
bracket in place.
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F-50
F-50
TROUBLESHOOTING AND REPAIR
STATOR REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.20 ā STATOR LOCATION
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 .030
gage should not penetrate the air gap any far-
ther than any tapered portion on the end of the
gage.
11. Reinstall the control box and fuel tank previ-
ously removed.
12. Replace the case wraparound cover.
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F-51
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
DESCRIPTION
This procedure will aid the technician in the removal and replacement of the rotor.
MATERIALS NEEDED
Rotor Puller Tool (See parts pages for the tool part number)
Impact Wrench
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F-52
F-52
TROUBLESHOOTING AND REPAIR
ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.21 ā ROTOR LOCATION
ROTOR
THROUGH BOLT
PROCEDURE
IMPORTANT
It is highly recommended that a new bearing be
installed before the rotor is secured to the
engine crankshaft.
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.
2. Thoroughly clean the engine crankshaft and the
rotor shaft where it mates to the engine crank-
shaft. Place the rotor on the crankshaft.
3. Remove the rotor from the engine crankshaft
using the Lincoln rotor-pulling tool. See instruc-
tions supplied with the tool.
3. When installing rotor thru-bolt, apply thread-
locking compound, (Locktite 2760 or equiva-
lent) torque the rotor thru-bolt to 22 to 24 ft-lbs.
IMPORTANT
4. After the rotor is secured to the engine crank-
shaft, check the run-out at the bearing outer
race. Run out should not exceed .015ā F.I.M.
Handle and store the rotor very carefully to
avoid damage to the windings.
If necessary, the cast end bracket can now be
removed from the engine.
5. See the stator removal and installation proce-
dures for further assembly instructions.
Replacing the Rotor
1. If the cast end bracket had been removed from
the engine, clean the mating surfaces and rein-
stall it on the engine at this time. Bolts should
be tightened to a torque of 22 to 24 ft-lbs.
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F-53
F-53
TROUBLESHOOTING AND REPAIR
RETEST AFTER REPAIR
PROCEDURE
No-load test values
High idle (No load) RPM: 3700-3800 RPM (61.7 ā 63.3 Hz)
Low idle RPM: 2250-2500 RPM (37.5 ā 41.7 Hz)
Weld terminal open Circuit Voltage (OCV):
Weld control at maximum: 70 ā 80 VDC
Weld control at minimum: 45 ā 60 VDC
Full load test values:
Weld output control set to maximum.
Output amps: 165 ā 190, Volts: 21 ā 27, RPM: 3300 ā 3650
Weld output set to minimum:
Output amps: 40 ā 55, Volts: 20 ā 28
Auxiliary receptacles with weld output control set to maximum:
230 Volt receptacles:
Load amps: 22. ā 25, Volts: 216 ā 250 VAC
120 Volt receptacles:
Load amps: 20.2 ā 24, Volts: 108 ā 130 VAC
NOTE: Values shown above are for a machine that is at normal full load temperature. Readings will
likely be slightly higher if machine is cold.
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F-54
F-54
NOTES
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G-1
G-1
TABLE OF CONTENTS - DIAGRAM SECTION
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
Wiring Diagram - Complete Machine Code 11516 (L13878) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Schematic ā Complete Machine Code 11516 (G6205) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Schematic ā Field Control / Idle PC Board (G4793-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4
* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-lay-
ered and are therefore considered to be unserviceable. Assembly drawings of these boards are
no longer provided.
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G-2
G-2
ElEcTrical DiaGramS
WiriNG DiaGram - cOmplETE machiNE cODE 11516 (l13878)
WIRING DIAGRAM - OUTBACK 185
77
GROUND STUD
ON CONTROL PANEL
FRONT
GND-J
76
R1
75
7
9
OIL
LE EL
MO
GND-G
GND-K
GND
V
DUL
224A
224
E
LOW
OIL
INDI
L.E.D.
C
ATOR
GND-C
B1
GND-F
C
BW
Y
BW
Y
HOUR METER
30A
3
5
3
11
BLUE
C
B2
GND-K
212
3A
20A 3B
J4
GND-D
GND-C
P4
5
5A
SILVE
R
BR
BR
5A
B
J6
1
2
3
4
5
6
5B
D
GND-I
210A
208A
NEUTRAL STU
ON CONTROL
210B
BLACK
6B
208
C
B3, 20A
PANEL BOTTOM
240 V
6
213B
GND-E
YR
W
RAP IN
215A
215
SILVE
R
IDLE
OLENOID
C
30A
B1
J5
6B
5B
OPPOSITE
DIRECTION
BW
6A
213A
S
S
OFF
S1
FUSE
12
230
BLACK
OIL
3R
D
209A
213
UT
HIG
W3
W4
IGNITION
W3A
ALT.
C
OIL
S
D1
A
O
+
ST
A
RTER
ELEC
EL-B
POS
211
LE EL
V
WRAP
TURN
1
(TOP)
H
CHOKE
L1
SOLENOID
ELECTRODE
SENSOR
(CLOSE WHEN
OIL LE
IS TOO L
SPARK
PLUG
210A
209
D
+
ENGIN
ST RTER
E
4T (TOP)
H
12
OL
ATTERY
V
EL
_
AC REACTOR
(BOTTOM)
A
V
T
+
O
W)
1ST (BOTTOM)
B
W1
W1A
NEG
GND-H
GND
R
FIEL
OTOR
D
2ND
W2
ENGINE
W2
+
13A
13
SLIP
RINGS
GENERATOR
SUPPORT
FRAME
WORK
C
5A
B4
WORK
-
200A
219
GROUND
261
260
14
8
10
200A
219
75
GND-I
GND-G 215
76
212
209
213
13 14
211
77
108
261
208A
260
224
224A
1
7
5
1
6
2
1
3
J3
10
J1
J2
4
6
12
B1 B2
B3 B4
FIELD / IDLER
PC
BOARD
A
L13878PRINT
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
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G-3
G-3
ElEcTrical DiaGramS
SchEmaTic - cOmplETE machiNE cODE 11516 (G6205)
5 0 6 2 G
ENGI
NEERING CONTROLLED
CHANGE
DETAIL:
RELEASED A.02 FROM X.
MANUFACTURER: No
GROUND STUD
ONCONT OL PANEL
FR NT
7
R
O
GND-G
GND-K
GND
82 VAC
9
GND-C
CB1
GND-F
30
A
3
5
3
11
CB2
3A
20
A
3B
J4
GND-D
5A
GND-C
5
5A
SILVER
J6
5B
NEUTRA
ON CONT
PANE OTTOM
L
R
B
STUD
OL
6B
L
CB3, 20
A
240
V
6
GND-E
5B
SILVER
CB1
J5
6B
WRA TURNS
P
4
6A
INOPPOSIT
E
30A
DIRECTIONS
12
D1
TOP
W3A
3RD
ELEC
W3
W4
AC REACTOR
EL-B
62 VAC
+
< 0
Ā°
ELECTRODE
CHOKE
under front edge
front top left
4TH (T P)
O
of control box ( LEFT)
both top
right
1S (BOTTOM)
BOTTOM
W1
W1A
T
AC
REACTOR
both
64 VAC
< 90
top front
Ā°
R
OTOR
FIEL
D
W2
MAY OPEN IF
2N
D
Pos. brush is closest to lamination
+
WORK
_
MACHIN IS
E
13A
13
OVERLOADED
9 ohms
D
SLI
30 min to 50 V C max
RINGS
P
C
B4
14
WORK
Boost Coils
Used to supply bd.
power during
heavy weld short
ckt conditions.
6v in = 72 v out
-
UNDER
under front edge
of control box ( RI HT)
CONTR
OL
brushes lower front
under cover
G
BOX
1. 2 volts A @ 55 HZ
Hi rpm with a100W bulb
on 115 aux
C
9
7
200A
219
indicates quick
connections
4 places
260 261
no load = 26mV.
J2-3
J2-4 B3
B4
J1-11
J1-5
B1
B2
FLASH
CURRENT ATH
P
20
4.7V
77
J3-6
J1-8
GND-J
76
D
RIVER
+
-
R1
CIRCUIT
13 kHz.
SUPPRESSOR FOR
D1 RECTIFIER
1.4V
J1-12
J1-6
8
OIL
LE EL
MO UL
+
-
insulated inline
connector
top engine area
75
J3-5
J3-8
.05
V
D
s
130V
38J
5K
E
0.1
topleft engine
10
near LE
D
Kohlers' part
224A
224
BW
Y
BW
Y
B
+10 VOLT
+10
V
J1-9
J1-2
J3-4
LO
(R
W
E
OIL
D)
REGULATOR
CIRCUIT
BLUE
name plate area
HOUR METER
Kohlers' part
GND-G
GND-K
inside control
box bottom left
+10
V
LOAD
SENSOR
J3-3
J3-9
J1-3
BR
BR
212
1
2
3
4
5
6
IDLE TIMER
(12 S C.)
GND-I
210A
210B
208 board powe
213B
E
BLACK
r
208A
213A
215
215A
IDLE
S
OLENOI
D
magneto type
RW
There is an extra fuse
with the fuse holder
230
OFF
15 ohms 12 volt dc
top left rear engine
Energized for LOW idle
( spring on solenoid to hi )
S1
FUSE
BLACK
213
J2-1
209A
R
IGNITION
OIL
ALT.
AUTO
C
S
10 amp 12vdc
under white cover
back of control box
LECO part
ST
A
RTER
D
J3-10
Board chematic : G4793
S
SOLENOI
7 Ohms
HIGH
POS
+
left side engine
SPARK
PLUG
CR1
CR1
12
V
ENGINE
ST RTER
START
209
OIL
EL
SENSOR
(CLOSE WHEN
OIL LEVEL
OLT
ATTERY
front bottom right
Battery M ST be > 6 VDC to use pull start cord.
A
J3-7
SEE SOLENOI
BELOW
D
DETAIL
LEV
left front panel
B
back wall of control box
D
U
If removed (gone) or < 6vdc, engine will not start with pull cord.
( reason, CR 1 relay does not pull in on board)
NEG
IS TOO L
OW)
GND-H
GND
Air
filte
r
left front
,
intake
is on backside of filter asbly.
A
ll engine components are
inside the engine housing.
Engine parts are fro Kohle
Engine muffle is located in the middle RI
Engine oil fill / check / drai LEFT or RI HTsides low on engine.
ENGINE
GENERATOR
SUPPORT
FRAME
m
r
r
GHT side area.
GROUND
n
G
The black oil cover is fill, the gray one has a dip stick on it
Bolt in casting is drain plug. Spark plugs are resistor type
Battery or Pull start. Pull is done from the left rear side engine
Engine is a Kohle
r
CS12.75 aluminum block
coil
w/ case iron sleeve. 12.75H
P
@3600RPM. ir Cooler
A
1 cylinder. Manual choke (Front on left name plate)
Fuel consumption charts in IM manual
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
frame
ground
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR AN
Y
PURPOSE WITHOU THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
T
SOLENOID DETAIL
M
ANUFACTURING TO
L
ERANC
E
P
ER
E2056
CONTROL: CLEVE
L
AND
SCA E:
L
UNLESS OTHERWISE SPECIFIED TOLERANCE:
EQUIPMENT TYPE:
1
1
OUTBACK 185
PAGE ___ OF ___
ON
ON
ON
MATERI
WITH PU
2
3
A
PLAC
PLACE
LL ANGL
TO
LISHED STANDARDS.
E
D
D
E
E
L
ECIMAL
CIMALS IS
.5 OF
ERANC ("
S
I
Ā±
S
Ā±
.02 in.
(
0.
Ā±
0.5 mm)
to starter motor
NONE
IF PRIN
DRAWN BY:
ENGINEER:
APPROVED:
mpatrzyk
.
00
A
2
DE
TO
i
n.
GREE
GREE
(
Ā±
0
5
mm)
DOCUMEN
T
DOCUMEN
T
T
ED
E
S
I
S
Ā±
SUBJECT:
MA ERIAL
REVISION:
NUMBER:
MACHINE SCHEMATC
REFERENCE:
@
A
1
SIZ
A
L
E
"
)
A
AP
-
M
t
UNITS:
B
T
APPROVA
DATE:
L
PROJEC
T
G6205
UF
3/6/2009
A
CRM40758
DISPOSI ION:
T
NUMBER:
INCH
DO NO
T
SCAL HIS DR
E
T
A
WING
-
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
OUTBacKĀ® 185
Download from Www.Somanuals.com. All Manuals Search And Download.
G-4
G-4
ElEcTrical DiaGramS
SchEmaTic - FiElD cONTrOl / iDlE pc BOarD (G4793-1)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
OUTBacKĀ® 185
Download from Www.Somanuals.com. All Manuals Search And Download.
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