Lincoln Electric SVM204-A User Manual
Safety Depends on You
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Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READING THIS MANUAL AND THE
SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
SVM204-A
October, 2010
OUTBACK®185
For use with machine code number: 11516
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 1.888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
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2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
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SAFETY
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
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:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
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.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” 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.
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.
ARC RAYS can burn.
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.
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.
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
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
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 ventilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized
steel.
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 exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
vapors
to
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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 manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s 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.
6.a.
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjcent areas. Avoid welding near hydraulic
lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
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.
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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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.
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.
6.h. Also see item 1.c.
Remove fire hazards from the welding area.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
If
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.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
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,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, 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.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
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iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
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1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
v v
SAFETY
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. 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 manufacturer’s
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 complete 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 equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems 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;
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h) the time of day that welding or other activities are to be carried out.
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vi vi
SAFETY
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. 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 equipment, 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 manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equipment 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 manufacturer’s 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 connection 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.
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_________________________
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) product standard for arc welding equipment.”
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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
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-591
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A-1 A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Pre-Operation Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
TABLE OF CONTENTS - INSTALLATION SECTION
Location and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Electrical and Welding Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Plugs and Hand-Held Equipment, Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Premises Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Electrical Devices used with the OUTBACK® 185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
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OUTBACK® 185
A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS -
OUTBACK® 185 (K2706-1)
INPUT - GASOLINE ENGINE
Make/Model Description Speed (RPM) Displacement Ignition Capacities
System
KOHLER 1 cylinder
CS 12.75 4 cycle 1825RPM Low Idle (360 cc) Start; (24.9L)
air-cooled 3400RPM Full Load
OHV gasoline Bore x Stroke
12.75 HP @ Choke (1.1L)
3600 RPM 3.35” x 2.48”
Aluminum Block
w/ Cast Iron Sleeve
3750RPM High Idle 21.96 cu. in
(85 mm x 63mm)
Electric & Recoil
Manual
Fuel: 6.86 gal.
Oil: 1.2 Qts.
RATED OUTPUT - WELDER
AMPS @ DC CONSTANT CURRENT DUTY CYCLE VOLTS @ RATED AMPERES
100 100% 25
130 60% 25
150 20% 25
185 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
HEIGHT WIDTH DEPTH WEIGHT
25.47 in. 21.12 in. 31.48 in. 310.0 lbs.
646.94 mm 536.45 mm 799.59 mm 140.6 kg
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
0° F TO 104° F (-18° C TO 40° C) -40° F TO 131° F (-40° C TO 55° C)
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OUTBACK® 185
A-3 A-3
INSTALLATION
SAFETY PRECAUTIONS
Read this entire installation section before you
start installation.
WARNING
Do not attempt to use this equipment until you
have thoroughly read all operating and maintenance manuals supplied with your machine. They
include important safety precautions, detailed
engine starting, operating and maintenance
instructions, and parts lists.
Hazards of Electric Shock, Engine
Exhaust & Moving Parts
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
or electrode with skin or wet clothing.
• Insulate yourself from work and
ground.
• Always wear dry insulating gloves.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas
or vent exhaust outside.
• Do not stack anything on or near
the engine.
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
Only qualified personnel should install, use, or
service this equipment.
LOCATION AND VENTILATION
Whenever you use the
cooling air can flow around the machine’s 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.
OUTBACK® 185
The
the machine in puddles or otherwise submerge it in water.
Such practices pose safety hazards and cause improper
operation and corrosion of parts.
Always operate the
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.
OUTBACK® 185
must be used outdoors. Do not set
OUTBACK® 185
, be sure that clean
with the case roof on
STORING
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.
2. If you will be storing the machine for over 30 days, you
should drain the fuel to protect fuel system and carburetor 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.
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.
7. Store in a clean, dry area.
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OUTBACK® 185
A-4 A-4
INSTALLATION
STACKING
OUTBACK® 185 machines CANNOT be stacked.
TILTING
Place the machine on a secure, level surface whenever you use it or store it. Any surfaces you place it on
other than the ground must be firm, non-skid, and
structurally sound.
The gasoline engine is designed to run in a level position 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.
LIFTING
The OUTBACK® 185 should be lifted by two people.
(See Technical Specification page for weight). The
LowLift™ grab bars on both ends make lifting easier.
PRE-OPERATION ENGINE SERVICE
Read and understand the engine operating and
maintenance instructions supplied with this machine
before you operate the OUTBACK® 185.
OIL
The OUTBACK® 185 is shipped with the engine filled
with SAE 10W30 oil. CHECK THE OIL LEVEL
BEFORE YOU START THE ENGINE. This is an added
precaution. Do not screw in dipstick when checking oil
level. DO NOT OVERFILL. Be sure the fill plug is tight
after servicing.
FUEL
Fill the fuel tank with clean, fresh, regular grade (minimum 87 octane lead free gasoline. DO NOT MIX OIL
WITH GAS. The OUTBACK® 185 capacity is approximately 6.8 gallons (25.74 Liter). DO NOT OVERFILL,
allow room in the fuel tank for fuel expansion.
SPARK ARRESTER
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.
CAUTION
WARNING
• Keep hands away from muffler or HOT engine
parts.
• Stop the engine when fueling.
• Do not smoke when fueling.
• Remove fuel cap slowly to release pressure.
• Do not overfill tank.
• Wipe up spilled fuel and allow fumes to clear
before starting engine.
• Keep sparks and flame away from tank.
------------------------------------------------------------------------
An incorrect additional arrester may lead to damage to the engine or adversely affect performance.
------------------------------------------------------------------------
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OUTBACK® 185
A-5 A-5
1
2
7
8
4
6
3
9
10
5
INSTALLATION
OUTBACK® 185 OUTPUT CONNECTIONS
1. CURRENT CONTROL DIAL
2. WELD OUTPUT TERMINALS (2)
3. GROUND STUD
4. CIRCUIT BREAKERS (2) - 20 AMP
5. CIRCUIT BREAKER 30 Amp
6. RECEPTACLE - 240 VOLT, 50 AMP
ELECTRICAL OUTPUT CONNECTIONS
See Figure A.1 for the location of the current control
dial, weld output terminals, ground stud, circuit breakers, 240 and 120 volt receptacles.
WELDING CABLE CONNECTIONS
Cable Size and Length
Be sure to use welding cables that are large enough.
The correct size and length becomes especially important 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 distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
FIGURE A.1
7. DUPLEX RECEPTACLE (2)- 120 VOLT, 20 AMP
8. HOURMETER
9. ENGINE SWITCH
10. CHOKE
100-150 ft (30-46 m)
150-200 ft (46-61 m)
200-250 ft (61-76m)
TABLE A.1
RECOMMENDED WELDING CABLE
SIZE AND LENGTH
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable
Length
0-50 ft (0-15m)
50-100 ft (15-30 m)
125 Amps
30% Duty Cycle
6 AWG
5 AWG
3 AWG
2 AWG
1 AWG
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OUTBACK® 185
A-6 A-6
Cable Installation
INSTALLATION
MACHINE GROUNDING
Install the welding cables to your OUTBACK® 185 as
follows. See Figure A.1 for the location of parts.
1. The gasoline engine must be OFF to install weld-
ing cables.
2. Remove the 1/2-13 flanged nuts from the output
terminals.
3. Connect the electrode holder and work cables to
the weld output terminals. Normally, the electrode
cable is connected to the positive (+) output stud.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding
(the “work”) is securely connected to the work
clamp and cable.
6. Check and tighten the connections periodically.
CAUTION
• Loose connections will cause the output studs to
overheat and the studs may eventually melt.
• Do not cross welding cables at output stud connec-
tion. Keep isolated and separate from one another.
------------------------------------------------------------------------
Lincoln Electric offers a welding accessory kit with #6
welding cables. See the ACCESSORIES section of
this manual for more information.
Because this portable engine driven welder or generator creates its own power, it is not necessary to connect
its frame to an earth ground, unless the machine is
connected to premises wiring (your home, shop, etc.).
To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power,
must:
a) be grounded to the frame of the welder using a
grounded type plug
or
b) be double insulated
When this welder is mounted on a truck or trailer, the
machine grounding stud must be securely connected to the metal frame of the vehicle.
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
stud marked with the symbol is provided on the
front of the welder.
WARNING
DO NOT GROUND MACHINE TO A PIPE WHICH CARRIES EXPLOSIVE OR COMBUSTIBLE MATERIAL.
------------------------------------------------------------------------
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For more information on welding , see WELDING
OPERATION in the OPERATION section of this manual.
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OUTBACK® 185
A-7 A-7
INSTALLATION
PLUGS AND HAND HELD EQUIPMENT
For further protection against electric shock, any electrical equipment connected to the generator receptacles must use a three-blade, grounded type plug or an
Underwriter’s Laboratories (UL) approved double insulated tool with a two blade plug.
WARNING
Never operate this machine with damaged or
defective cords. All electrical equipment must be
in safe operating condition.
------------------------------------------------------------------------
AUXILIARY POWER RECEPTACLES
The control panel of the OUTBACK® 185 features
three auxiliary power receptacles:
• Two 20 amp,120 volt duplex (double outlet)
receptacle.
• A 50 amp, 240 volt single outlet receptacle.
See Figure A.1
PREMISES WIRING
The OUTBACK® 185 is not recommended for premises wiring. The OUTBACK® 185 does not have a combined 120/240 volt receptacle and cannot be connected to a premises as described in other Lincoln literature.
The OUTBACK® 185 is intended only for backup,
intermittent use power. Certain electrical devices cannot be powered by the OUTBACK® 185. Refer to
Table A.2 for these devices.
CIRCUIT BREAKERS
Auxiliary power is protected by circuit breakers. When
the machine is operated in high temperature environments, the breakers may tend to trip at lower loads
than normally.
CAUTION
NEVER BYPASS THE CIRCUIT BREAKERS. WITHOUT OVERLOAD PROTECTION, THE UNIT COULD
OVERHEAT AND/OR CAUSE DAMAGE TO THE
EQUIPMENT BEING USED.
Through these receptacles the machine can supply up
to 5700 watts surge or 5200 watts continuous of singlephase 60 Hertz AC power. The machine output voltages meet UL standards and fall within ± 10% of the
rated voltage.
------------------------------------------------------------------------
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OUTBACK® 185
A-8 A-8
INSTALLATION
CAUTION
Certain Electrical devices cannot be powered by the OUTBACK® 185. See Table A.2
TABLE A.2
ELECTRICAL DEVICE USE WITH THE OUTBACK® 185
Type
Resistive
Capacitive
Inductive
Common Electrical Devices
Heaters, toasters, incandescent
light bulbs, electric range, hot
pan, skillet, coffee maker.
TV sets, radios, microwaves,
appliances with electrical control.
Single-phase induction motors,
drills, well pumps, grinders, small
refrigerators, weed and hedge
trimmers.
Possible Concerns
NONE
Voltage spikes or high voltage
regulation can cause the capacitative elements to fail. Surge
protection, transient protection,
and additional loading is recommended for 100% fail-safe operation. DO NOT RUN
THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE TYPE
LOADS.
These devices require large
current inrush for starting. (See
Table B.3, AUXILIARY POWER
APPLICATIONS, in the OPERATION 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.
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Capacitive / Inductive
The Lincoln Electric Company is not responsible for any damage to electrical components
improperly connected to a OUTBACK® 185.
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Computers, high resolution TV sets,
complicated electrical equipment.
OUTBACK® 185
An inductive type line conditioner along with transient and
surge protection is required,
and liabilities still exist.
DO NOT USE THESE DEVICES
WITH A OUTBACK® 185.
B-1 B-1
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
TABLE OF CONTENTS - OPERATION SECTION
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
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OUTBACK® 185
B-2 B-2
OPERATION
SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts
or electrode with skin or wet
clothing.
• Insulate yourself from work and
ground.
• Always wear dry insulating
gloves.
FUMES AND GASES
can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
WARNING
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas
or vent exhaust outside.
• Do not stack anything on or near
the engine.
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
Only qualified personnel should install, use, or
service this equipment.
Observe additional Safety Guidelines detailed
throughout this manual.
WELDING SPARKS
can cause fire or
explosion
• Keep flammable material away.
• Do not weld on containers that
have held combustibles.
ARC RAYS
can burn.
• Wear eye, ear and body
protection.
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OUTBACK® 185
B-3 B-3
OPERATION
GRAPHIC SYMBOLS USED ON THIS EQUIPMENT OR IN THIS MANUAL
WARNING /
CAUTION
OIL
FUEL
WORK CLAMP
FAST
CHOKE
AIR CLEANER
CIRCUIT
BREAKER
GROUND
(AUXILIARY
POWER)
ELECTRODE
WELDING ARC
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SLOW
AUTO IDLE
ENGINE OFF
ENGINE START
OUTBACK® 185
B-4 B-4
OPERATION
GENERAL DESCRIPTION
The OUTBACK® 185 is designed for commercial use
welder/generator applications. As a welder it provides
185 amps of DC constant current for welding with DC
stick electrodes. A single dial lets you select a full
range of welding output from 50 to 185 amps.
As a generator it can supply up to surge watts or continuous watts of 120 / 240 volt, single-phase AC power.
The machine is portable.
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
Welder
The OUTBACK® 185 provides excellent constant current DC welding output for stick (SMAW) welding.
Generator
The OUTBACK® 185 gives smooth AC generator output for continuous auxiliary power usage within the
engine manufacturer’s required maintenance recommendations.
OPERATIONAL FEATURES AND
CONTROLS
DESIGN FEATURES AND
ADVANTAGES
• 185 amp DC constant current welding for stick
electrodes.
• Lightweight / portable.
• Full range, continuous welding output control with
a single knob.
• Automatic shutdown under low oil level condition.
• Hour Meter Standard.
• Surge watts or Watts of continuous 120 / 240 volt
single phase AC auxiliary power.
• Kohler CS 12.75 HP overhead cam air-cooled
gasoline engine. Smooth running, long life.
WELDING CAPABILITY
The OUTBACK® 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 example, you can load the welder to 120 amps for ten minutes out of ten for a 100% duty cycle.
The current is continuously variable from 50 to 185
amps DC. The OUTBACK® 185 can, therefore, weld
with all 3/32”, 1/8” and most 5/32” diameter Lincoln DC
electrodes.
The OUTBACK® 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 machine’s 50 to
185 amp range.
The gasoline engine controls include a recoil starter,
choke and stop switch. See ENGINE OPERATION in
the OPERATION section of this manual for details
about starting, running, stopping, and breaking in the
gasoline engine.
LIMITATIONS
• The OUTBACK® 185 is not recommended for any
processes besides those that are normally performed using stick welding (SMAW) procedures.
• The OUTBACK® 185 is not recommended for pipe
thawing.
• 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 EQUIPMENT WHILE YOU ARE WELDING.
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OUTBACK® 185
B-5 B-5
1
2
7
8
3 or 4
6
9
10
12
11
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
FIGURE B.1
WELDER/GENERATOR CONTROLS
See Figure B.1 for the location of the following features:
1. CURRENT CONTROL DIAL: Adjusts continuous current output. The amperages on the dial correspond to
10. HOUR METER: Records the time that the engine has
run for maintenance purposes.
11. ENGINE CHOKE: Engine starting aid.
the approximate amperages needed for specific
Lincoln welding electrodes.
2. 30 AMP CIRCUIT BREAKER: Provide separate overload current protection for the 120 Volt and 240 Volt
Receptacles
3. WELD POSITIVE OUTPUT TERMINAL: Pro vides the
12. ENGINE SWITCH:
Used to start the engine, Select High Idle or Auto Idle
while the engine is running and stops the engine.
When placed in the “OFF” position, the ignition
circuit is de-energized to shut down the engine.
connection point for either the electrode holder or the
work cable. (Because the OUTBACK® 185 is a DC
output machine, either output terminal can be used for
either cable.)
4. WELD NEGATIVE OUTPUT TERMINAL: Provides the
connection point for either the electrode holder or the
When held in the “START” position, the engine
starter motor is energized.
When in “HIGH IDLE” ( ) position, the engine
will run continuously at high idle.
work cable. (Because the OUTBACK®185 is a DC output machine, either output terminal can be used for
either cable.)
5. GROUND STUD: Provides a connection point for connecting the machine case to earth ground for the safest
grounding procedure.
6. CIRCUIT BREAKER: Provides overload protection for
weld output terminals.
7.
CIRCUIT BREAKERS (2): Provide separate overload current protection for the 120 volt and 240 volt receptacles
8. 240 VOLT RECEPTACLE: Connection point for supplying 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.
When in “AUTO IDLE” ( / ) position, the
engine will run continuously and the idler operates as
follows:
• 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.
• Auxiliary Power
With the engine running at low idle and auxiliary
power for lights or tools is drawn (approximately 0150 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.
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OUTBACK® 185
B-6 B-6
OPERATION
ENGINE OPERATION
Starting/Shutdown Instructions
Be sure all Pre-Operation Engine Service has been
performed. Also, Read owners manual before starting
for the first time. (See INSTALLATION section)
Remove all loads connected to the AC power receptacles. Before starting, first open the fuel shutoff valve.
Always pull the choke control out when starting the
engine; cold, warm or hot.
Turn the engine switch to the “Start” position and
crank the engine until it starts, slowly return the choke
control to the full “in” position (choke open), and turn
the switch to the Auto Idle ( / ) position.
Do not turn the switch to the “start” position while the
engine is running because this will cause damage to
the ring gear and/or starter motor.
Stopping the Engine
Remove all welding and auxiliary power loads and
allow engine to run for a few minutes to cool the
engine.
Break-in Period
It is normal for any engine to use larger quantities of oil
until break-in is accomplished. Check the oil level
twice a day during the break-in period (about 50 running hours). Change the oil after the first 5 hours of
operation. See the Engine Instruction Manual for further details.
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.
-----------------------------------------------------------------------
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.
Stop the engine by placing the engine switch in the
“Off” ( ) position.
WARNING
Close the fuel valve when the machine is
transported to prevent fuel leakage from
the carburetor.
------------------------------------------------------------------------
Typical Fuel Consumption
KOHLER CS 12.75 HP
NO LOAD
2250 R.P.M .75
NO LOAD .40 GALLONS/HOUR
3750 R.P.M. 1.51 ( LITERS/HOUR)
DC CC WELD OUTPUT .73 GALLONS/HOUR
100 AMPS, 25 VOLTS 2.77 ( LITERS/HOUR)
AUXILIARY POWER .99 GALLONS/HOUR
5200 KVA 3.74 ( LITERS/HOUR)
. .20 GALLONS/HOUR
( LITERS/HOUR)
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OUTBACK® 185
B-7 B-7
WELDING OPERATION
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
or electrode with skin or wet clothing.
• Insulate yourself from work and
ground.
• Always wear dry insulating gloves.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas
or vent exhaust outside.
• Do not stack anything on or near
the engine.
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
Only qualified personnel should install, use, or
service this equipment.
The OUTBACK® 185 can deliver from 50 to 185
amps of welding output current . Output can be
adjusted by setting the current control dial on the output control panel.
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 approximate amps needed to weld using specific Lincoln
welding rods. Table B.2, WELDING APPLICATIONS,
give you the recommended dial settings based on the
thickness of the work and the size and type of rod
you’re using.
TO USE THE OUTBACK® 185 FOR WELDING:
1. Remove the flange nuts from the weld output terminals and place the work and electrode welding
cables over the terminals. See Figure B.1 and
B.1a. Replace and tighten the flange nuts
securely. Be sure the connections are tight.
2. Select the appropriate electrode. See Table B.2
3. Attach the work clamp securely to the work you are
welding.
OPERATION
4. Insert the electrode into the electrode hold
5. Set the current control dial to the desired output
current .
6. Start the gasoline engine.
See ENGINE OPERATION in this section of
the manual.
7. Strike an arc and begin welding.
AFTER YOU FINISH THE WELD:
1. Stop the gasoline engine. See ENGINE OPERATION 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 OUTBACK® 185 for
welding, disconnect the welding cables from the weld
output terminals. Reattach the flange nuts and leave
them on the terminals.
For DC+ welding, the electrode cable is to be connected
to the “+” output stud and work cable to the “-” output
stud. (For DC- welding, reverse these connections.)
Semi-automatic Wire Welding with a Lincoln Wire
Feeder/Welder
The
OUTBACK® 185
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.
Plasma Cutting with Lincoln Pro-Cut 25.
OUTBACK® 185
The
supply up to 5,200 watts continuous input power to a ProCut 25. The Pro-Cut will work satisfactorily under the following conditions:
1. Set the Current Control on the
185 amp position. (Higher Settings may result in a
shutdown of the Pro-Cut 25.)
2. Leave the "ON/OFF" switch on the Pro-Cut "OFF"
until the OUTBACK® 185 has been started and is at
full operating speed.
er.
generator power can be used to
generator power can be used to
OUTBACK® 185
to the
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OUTBACK® 185
B-8 B-8
120V Receptacle Operation:
• Set the Output Control on the Pro-Cut 25 no higher
than the 15 amp position.( Higher settings may cause
circuit breaker on the
• Maximum material thickness that can be cut is 1/4".
240V Receptacle Operation:
• The Pro-Cut 25 may be used for its full range of control.
• Maximum material thickness that can be cut is 3/8".
OUTBACK® 185
OPERATION
to trip.)
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).
You can use Table B.3, AUXILIARY POWER APPLICATIONS, to determine the wattage requirements of
the most common types of loads you can power with
the OUTBACK® 185 Be sure to read the notes at the
bottom of the table.
TO USE THE OUTBACK® 185 AS AN AUXILIARY
POWER SUPPLY:
AUXILIARY POWER OPERATION
1. Start the gasoline engine. See ENGINE OPERA-
WARNING
Be sure that any electrical equipment plugged into the
generator AC power receptacles can withstand a ±10%
voltage and a ±5% frequency variation. Some electronic devices cannot be powered by the OUTBACK®
185 Refer to Table A.2, ELECTRICAL DEVICE USE
WITH THE OUTBACK® 185, in the INSTALLATION
section of this manual.
TION in this section of the manual.
2. Set the current control dial on the output control
panel to “MAX.” See Figure B.1.
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
The OUTBACK® 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
AWS ELECTRODE
CLASSIFICATION ELECTRODE TYPE POLARITY
E6010 FLEETWELD® 5P DC+ 50-75 75-135 90-175
E6011 FLEETWELD® 35 DC+ 50-75 70-110 80-145
E6011 FLEETWELD® 180 DC+ 50-80 55-110 105-135
E6013 FLEETWELD® 37 DC± 70-95 100-135 145-180
E7018 EXCALIBUR® 7018 DC+ 70-100 90-125 125-185
E7018 JETWELD® LH-73 DC+ 65-85 90-125 130-185
E708-17 & E308L-17
ENi-CI SOFTWELD® 99Ni DC+ 50-80 80-110 100-140
- WEARSHIELD® ABR DC+ - 50-150 50-185
BLUE MAX® 308/308L AC-DC
SHEET THICKNESS THINNER 1/8 AND THICKER
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.
CURRENT RANGE (AMPS)
3/32 SIZE 1/8 SIZE 5/32 SIZE
DC+ 50-80 75-110 95-150
1/8 AND
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OUTBACK® 185
B-9 B-9
AUXILIARY POWER APPLICATIONS
Suggested Power Applications Running Watts *Start-up Watts
*Air Compressor - 1 HP 2,000 4,000 - 8,000
*Air Compressor - 3/4 HP 1,250 3,100 - 5,000
*Airless Sprayer - 1/3 HP 600 1,500 - 2,400
Chain Saw 1,200
Circular Saw 1,200
Coffee Maker 1,000
*Deep Freezer 500 750 - 2,000
*Electric Motor - 1 HP 1,000 2,500 - 4,000
Electric Range (1 element) 1,500
Electric Skillet 1,250
*Furnace Fan - 1/3 HP 1,200 3,000 - 4,800
Portable Grinder (4 1/2”) 600
Portable Grinder (7”) 2,000
Halogen Work Light 500
Hand Drill - 1/4” 500
Hand Drill - 3/8” 700
1500 Watt Heater 1,750
Hedge Trimmer 450
Light Bulb 100
Reciprocating Saw 900
Radial Arm Saw 2,600
Radio 50
*Refrigerator/Freezer (small) 600 1,500 - 2,400
Slow Cooker 200
*Submersible Pump - 1 HP 1,000 2,500 - 4,000
*Sump Pump 600 1,500 - 2,400
Toaster 1,100
Weed Trimmer 500
Lincoln Wire Feeder/Welder 4,000
OPERATION
TABLE B.3
(Continuous) (Peak)
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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.
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OUTBACK® 185
B-10 B-10
NOTES
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OUTBACK® 185
C-1 C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Options / Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
TABLE OF CONTENTS - ACCESSORIES SECTION
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OUTBACK® 185
C-2 C-2
ACCESSORIES
OPTIONS/ACCESSORIES
The following options/accessories are available for
your OUTBACK®185 from your local Lincoln
Distributor:
Accessory Kit (K875) – Includes the following:
• Twenty feet (6.1 meters) of #6 AWG electrode cable
with lug.
• Fifteen feet (4.6 meters) of #6 work cable with lugs.
• Work Clamp
• Headshield with No. 10 filter
• Insulated electrode holder and sample electrodes
150 amp capacity.
Undercarriage (K2722-1) - A two-wheeled, hand movable undercarriage is available for field installation.
Rotor Removal Kit (S20925) - A service kit with thru
bolt and impact bolt’s 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 Outback®
185 when not in use. Made from attractive red canvas
which is flame retardant, mildew resistant and water
repellent.
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OUTBACK® 185
D-1 D-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Engine Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Engine Maintenance Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Operational Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Major Component Locationss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
TABLE OF CONTENTS - MAINTENANCE SECTION
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OUTBACK® 185
D-2 D-2
MAINTENANCE
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OUTBACK® 185
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