Lincoln Electric OUTBACK 145 User's Manual
Contents
1. 104 S SIUL 310 6666 n Oa an EHE HOLMS HOLMS NOH lt O1SNNE ONO 3 111 M WOLLOG 1041409 NO 115 WHLNIN as LU 9 E EICH L in 1HOddhs TOHINOO HOLVH3N39 1 NO GALS ONE 102 102 T 2102 931 009 om Ho 001 vooc 9202 202 ER 902 ELECTRIC OUTBACK 145 971 MOVELNO INVHOVIG DIMENSION PRINT iis F 2 89Z LZIN OUTBACK 145 ALANG 1 1 ALIAVHO 3NION3 SALON NOTES OUTBACK 145 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Chinese Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes 0 los electrodos bajo carga con la piel moja d a Aislese del trabajo de la tierra Ne laissez ni la peau ni des v te ments mouill s2. 583 82 gt 018 2 lt CL TMHORSME EDT FEU ELE E H8 GE 89 ABA DL ERR 8 SE EROR ST RI 5 0 SSE AIBAIE HA ETAP gi JS gll y Gail all x World s Leader Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
3. Gul oa hia jua A Ae SE Ms Ai Als e call 8 6 Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la antes de iniciar cualquier servicio e D branchez le courant avant l entre tien 6 Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas e Desligue a corrente antes de fazer servico e toque as partes el tricas nuas 2501 j A4 v Fe 2 e na eiio AAS 08 jud dell e Do not operate with panel open guards off 6 No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas e e dE GTI EUR 2 Ez e OHH ALS jai jia Al AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese SIS Chinese Ss LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR
4. WC TE TEE SIONN NEE SLACKING WEE DEE RER eeu d dn Pre Operation Engine 0 0 RE EE e EUGENE A nn Spark yi Electrical and Welding Connections Machine Grouriding lement Plugs and Hand Held Equipment Auxiliary Power Receptacles A 6 iia eet A 6 Circuit EE A 6 Electrical Devices used with the OUTBACK 145 A 7 epu o T Section B Safety Ee TEE 1 ESS EE 2 3 Recommended Applications wit henri niet ans nat A 3 Operational Features and 6005 3 Design Features and 04 0 3 Welding EE 3 le B 3 Controls and Settings B 4 Welder Generator Controls ss B 4 Engine 252 B 5 Welding B 6 Auxiliary 0 7 Electrode selection Guide B 7 Auxiliary Power Application sise B 8 000850165 5 Section General Options Accessories nennen C 1 Eu E Section D Safety Precautions D 1 Routine and Periodic Engine D 1 D 2 ge UNE e dl e E Section E How to Use Troubleshoo
5. CIT FIGURE 1 CURRENT CONTROL 2 WELD OUTPUT TERMINALS 2 3 GROUND STUD 4 CIRCUIT BREAKER 20 Amp ELECTRICAL OUTPUT CONNECTIONS See Figure 1 for the location of the current control dial weld output terminals ground stud circuit break ers 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 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 distance from the welder to the work and_back to the welder Cable diameters are increased for long cable lengths to reduce voltage drops 5 RECEPTACLE 240 VOLT 50 AMP 6 DUPLEX RECEPTACLE 2 120 VOLT 20 AMP 7 HOURMETER TABLE A 1 RECOMMENDED WELDING CABLE SIZE AND LENGTH TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable 125 Amps Length 30 Duty Cycle 0 50 ft 0 15m 6 AWG 50 100 ft 15 30 m 5 AWG 100 150 ft 30 46 m 3 AWG 150 200 ft 46 61 m 2 AWG 200 250 ft 61 76m 1 AWG OUTBACK 145 a INSTALLATION Pro Cable Installation Install the welding cables to your OUTBACK 145 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
6. 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 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 4750 Peak watts Be sure to start the largest loads first OUTBACK 145 x E ACCESSORIES C1 OPTIONS ACCESSORIES The following options accessories are available for your OUTBACK 145 from your local Lincoln Distributor ACCESSORY KIT K875 Includes the following Twenty feet 6 1 meters of 6 AWG electrode cable with lug Fifteen feet 4 6 meters of 6 work cable with lugs Work Clamp Headshield with No 10 filter Insulated electrode holder and sample electrodes 150 amp capacity UNDERCARRIAGE K2722 1 A two wheeled hand movable undercarriage is available for field installa tion ROTOR REMOVAL KIT S20925 A service kit with thru bolt and impact bolt s for removing the generator rotor from tapered engine crank shaft OUTBACK 145 E MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING Have qualified personnel do all maintenance and troubleshooting work Turn the engine off before working inside the machin
7. 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 Table 8 3 GENERATOR POWER 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 OUTBACK 145 The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to a OUTBACK 145 OUTBACK 145 zi OPERATION uiis SAFETY INSTRUCTIONS WARNING 4 WARNING K e ELECTRIC SHOCK ENGINE EXHAUST can kill can kill 23 Use in open well ventilated areas Do not touch electrically live parts 0 or vent exhaust outside or electrode with skin or wet Do not stack anything on or near clothing the engine Insulate yourself from work and ground MOVING PARTS injure Do not operate with doors open or Always wear dry insulating guards off gloves Ys Stop engine before ser
8. 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 For more information on welding see WELDING OPERATION in the OPERATION section of this man ual MACHINE GROUNDING Because this portable engine driven welder or genera tor creates its own power it is not necessary to con nect 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 con nected to the metal frame of the vehicle In general if the machine
9. 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 5 Exposure to fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 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 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 idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable
10. 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 4 Insert the electrode into the electrode holder 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 OPERA TION in this section of the manual Allow the electrode and work to cool completely Remove the work clamp from the work Remove any remaining piece of electrode from the electrode holder 5 If you are finished using the OUTBACK 145 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 145 generator power can be used to supply up to 4250 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 Weld
11. Faulty field capacitor C1 Faulty stator field winding Faulty rotor all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility Loose connector to output stud Work not connected Electrode holder loose No open circuit voltage at output studs Open lead in weld circuit Faulty output bridge rectifier Faulty choke L1 Circuit breaker is open Loose or open connection with electrical plug in component Current control dial not at MAX No open circuit voltage at receptacle Check CB1 and CB2 Reset if tripped If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed OUTBACK 145 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION ENGINE PROBLEMS Recoil starter is hard to pull 1 Crankcase may be over filled with oil Check oil level Engine will not start or starts but 1 Water in engine from rain and runs rough with low power or condensation Remove spark plug and dry it if wet Blow low pressure compressed air in spark plug port while pulling recoil starter Re inst
12. Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 V V for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular pu
13. be firm non skid and structurally sound 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 LIFTING The OUTBACK 145 should be lifted by two people See Specification section 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 145 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 OIL YA The OUTBACK 145 is shipped with the engine filled with SAE 10W30 oil CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE This is an added precaution Do not screw in dipstick when checking oil level DO NOT OVERFILL Be sure the fill plug is tight after servicing FUEL Fill the fuel tank with clean fresh regular grade mini mum 87 octane lead free gasoline DO NOT MIX OIL WITH GAS The OUTBACK 1
14. external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed OUTBACK 145 sis TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION Major Physical or Electrical Damage is Evident No Generator power or welding output Generator power is available but unit will not weld Unit will weld but low or no generator power is available No auxillary power but machine has weld output CAUTION OUTPUT PROBLEMS Contact your local Lincoln Authorized Field Service Facility Check brushes for wear See Maintenance section Check for loose or faulty connections at brush holders Open lead in flashing or field circuit Rheostat R1 lead broke Dirty slip rings Faulty rheostat R1 Faulty field bridge rectifier D1
15. is on your right side the work cable should also be on your right side AR Connect the work cable to the workpiece as close as possible to the area being welded 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 Do not work next to welding power source Mar 95 x SAFETY ELECTRIC SHOCK kill 3 8 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 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 In semiautomatic or automatic wire weldi
16. the OUTBACK 145 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 work cable Because the OUTBACK 145 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 FIGURE B 1 6 240 VOLT RECEPTACLE Connection point for sup plying 250 volt power to operate one electrical device 7 120 VOLT DUPLEX RECEPTACLES 2 Connection point for supplying 120 volt power to operate one or has run for maintenance purposes 8 HOUR METER Records the time that the engine has run for maintenance purposes OUTBACK 145 x 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 NOTE Remove all loads connected to the AC power receptacles before starting the gasoline engine Put the ON OFF Switch in the position COLD ENGINE Open the fuel shutoff valve Place the choke lever in the CHOKE position a on the recoil starter handle until resistance is felt Pull the cord rapidly If the engine does not start open
17. 45 capacity is approx imately 6 8 gallons 25 74 Liter DO OVER FILL allow room in the fuel tank for fuel expansion SPARK ARRESTER Some federal state or local laws may require gaso line 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 An incorrect additional arrester may lead to age to the engine or adversely affect performance Stop engine when fueling Do not smoke when fueling Keep sparks and flame away from tank Do not leave unattended while fueling Wipe up spilled fuel and allow fumes to clear before starting engine Do not overfill tank fuel expansion may cause overflow Close fuel shut off valve when transporting not operating machine GASOLINE can cause fire or explosion ENGINE EXHAUST PARTS can kill can injure GASOLINE FUEL ONLY Use open well ventilated C3 Keep away from moving parts Do not operate with panels open or guards off area or vent exhaust outside MOVING OUTBACK 145 INSTALLATION P OUTBACK 145 OUTPUT CONNECTIONS c T T T S
18. Do not touch electrically live parts _ or electrode with skin wet cloth ing Insulate yourself from work ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use open well ventilated areas Do not stack anything on or near the engine 0 or vent exhaust outside MOVING PARTS Do not operate with doors open guards off Stop engine before servicing Keep away from moving parts Only qualified personnel should install use or service this equipment The OUTBACK 145 can deliver from 50 to 145 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 145 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 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 145 FOR WELDING 1 Remove the flange nuts from the weld output ter minals and place the work and electrode welding cables over the terminals See Figure B 1 and
19. ECTION GUIDE CLASSIFICATION ELECTRODE TYPE FLEETWELD 35 FLEETWELD 180 FLEETWELD 37 EXCALIBUR 7018 JETWELD LH 73 E7018 E7018 E708 17 amp E308L 17 BLUE MAX 308 308L AC DC 50 80 SOFTWELD 99Ni WEARSHIELD ABR THICKNESS ELECTRODE POLARITY e 3 32 SIZE 1 8 SIZE FLEETWELD 5P DC 50 80 DC CURRENT RANGE 5 5 32 SIZE 75 135 70 110 55 110 100 135 90 125 90 125 75 110 80 110 50 150 80 125 105 125 125 145 80 125 1 8 AND THINNER 1 8 AND THICKER OUTBACK 145 x B 8 B 8 OPERATION TABLE B 3 AUXILIARY POWER APPLICATIONS Suggested Power Applications Running Watts Start up Watts Continuous Peak 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 1 500 Hedge Trimmer 450 Light Bulb 100 Reciprocating Saw 900 Radial Arm Saw 2 600 Radio 50 Refrigerator Freezer small 600 1 500
20. IM973 145 For use with machines having Code Numbers 11517 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 thought ful 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 CU LP OPERATOR S MANUAL ISO 9001 Ce 3 1 ce E Design Copyright O Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com WARNING CALIFORNIA PROPOSITION 65 WARNINGS 4 Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEE
21. INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL 050 DE EQUIPO LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU Keep your head of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de 105 humos Utilice ventilaci n aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entliiftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o 6 exhaust o para remover fumo da zona respirat ria 8 gt 22 50 4 2 7 F v CRAVHAELT TIMELTFEL emnmammm 5 IE GE RH 5 5 EH7I 8 Wake 37 X 1 Ash 719774 858718 HSH OSA oe ul
22. P 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 amp Cutting ANSI Standard 249 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 FOR ENGINE 1 1h To avoid scalding do not remove the powered equipment 4 0 radiator pressure cap when the engine is hot 1 8 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 vaporiz ing 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 ELECTRIC AND MAGNETIC FIELDS may be dangerous
23. Stop the engine by placing the ON OFF switch in the OFF O position A WARNING Close the fuel valve when the machine is transported to prevent fuel leakage from the carburetor 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 run ning hours Change the oil after the first 5 hours of operation See the Engine Instruction Manual for fur ther 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 sys tem will shut the engine down The engine will not restart until sufficient oil is added Check oil level fre quently and add oil as required to the full mark on the dipstick DO NOT OVERFILL Typical Fuel Consumption SUBARU ROBIN EX30 NO LOAD 3750 30 GALLONS HOUR 1 12 LITERS HOUR DC CC WELD OUTPUT 80 AMPS 25 VOLTS 52 GALLONS HOUR 1 98 LITERS HOUR AUXILIARY POWER 4000 KVA 71 GALLONS HOUR 2 69 LITERS HOUR OUTBACK 145 x 56 OPERATION B 6 WELDING OPERATION WARNING ELECTRIC 5 can kill
24. They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists Hazards of Electric Shock Engine Exhaust amp Moving Parts WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts TR or electrode with skin or wet cloth ing 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 A 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 OUTBACKTM 145 be sure that clean 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 The OUTBACKTM 145 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 Always operate the OUTBACK 145 with the case roof on and all machine components c
25. YLINDER may explode 2 229 gt if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National El
26. aken 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 cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c 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 Do not use a welding power source for pipe thawing C
27. all spark plug 2 Spark plug may be faulty 3 Air filter element saturated with water and or oil Replace If all recommended possible areas 5 See of misadjustment have been Engine runs erratically or stops run 1 Engine is not fully warmed up checked and the problem persists ning and engine choke is in the fully contact your local Lincoln oper RUN position Authorized Field Service Facility 2 Engine requires service to head carburetor filters oil spark plug and or gas 3 Oil level to low Engine sputters but will not start 1 Bad gas bad filter air cleaner spark plug and or breather Arc is erratic and pops out 1 Check Work and Electrode cables for loose or faulty connec tion 2 Electrode may be wet CAUTION for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed OUTBACK 145 DIAGRAMS Jequunu y 10 eui eu 2196911 eu sjeued y jo euo uo y paysed s epoo 10 eu IS 104 eq jou lt
28. ating conditions change the oil after every 100 hours or once a year whichever occurs first If the engine is operated under heavy load or in high ambient temperatures change the oil every 50 hours 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 Owner s manual for specific oil recommendations FIGURE D 1 OIL DRAIN AND REFILL LOCATION Do not screw in dipstick to check oil FILL to FULL mark on dipstick recheck OIL DRAIN PLUG Cil drain Tighten dipstick firmly before starting FUEL Atthe end of each day s use refill the fuel tank to minimize moisture con densation 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 Owner s Manual for more information OUTBACK 145 p MAINTENANCE D 2 To service the pre cleaner Remove the cover Carefully remove the foam pre cleaner from the filter element 1 Wash in liquid detergent and water 2 Squeeze dry in a clean cloth 3 Saturate in clean engine oil 4 Squeeze in a clean absorbent clo
29. e Remove guards only when necessary to perform maintenance and replace them when the mainte nance requiring their removal is complete If guards are missing from the machine get replacements from a Lincoln Distributor See the EXPLODED VIEW AND PARTS LIST at the back of this manual Read the Safety Precautions in the front of this manu al and in the Subaru Robin Operating and Maintenance Instructions manual before working on the OUTBACK 145 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 mov ing parts when starting operating or repairing this machine ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE CAUTION To prevent the engine from accidentally starting dis connect the spark plug lead before servicing the engine See the Subaru Robin Owner s manual for ry 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 Subaru Robin Owner s manual shows engine maintenance replacement parts and numbers OIL Check the oil level after every 5 hours of operation or daily BE SURE TO MAINTAIN THE OIL LEVEL Change the oil the first time after 20 hours of opera tion Then under normal oper
30. ectrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information Jan 09 SAFETY E PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais to
31. ent is continuously variable from 50 to 145 amps DC The OUTBACK 145 can therefore weld with 3 32 1 8 and some 5 32 diameter Lincoln DC electrodes LIMITATIONS e The OUTBACK 145 is not recommended for any processes besides those that are normally performed using stick welding SMAW dures The OUTBACK 145 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 EQUIP MENT WHILE YOU ARE WELDING OUTBACK 145 x B OPERATION 4 CONTROLS AND SETTINGS 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 Guy 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 2 20 AMP CIRCUIT BREAKER Provides overload cur rent protection for the 120 Volt and 240 Volt Receptacles 3 WELD POSITIVE OUTPUT TERMINAL Provides the connection point for either the electrode holder or the work cable Because
32. entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Beriihren Sie keine stromfiihrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra ARPORABR 005 7 5nfdcomntoc t 9 7 29 5 89468 e 0 9608 8 5888 He zz su e zial gaal ge el d Ah ach AA ua Maus Lie Y Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos KE 600 0 0 90 96 rum 123 d Bae 2 Wear eye ear and body protection Prot jase los ojos los 01405 y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und perschutz Use protec o para a vista ouvido e corpo HEUSHHERMARELTT ORME ez 719 Sol 2878 oua y cil yal pus 6 1 3 READ AND UNDERSTAND THE MANUFACTURER S
33. he INSTALLATION section of this manual GENERAL INFORMATION The OUTBACK 145 is rated at 4750 Peak watts or 4250 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 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 APPLI CATIONS to determine the wattage requirements of the most common types of loads you can power with the OUTBACK 145 Be sure to read the notes at the bottom of the table TO USE THE OUTBACK 145 AS AN AUXILIARY POWER SUPPLY 1 Start the gasoline engine See ENGINE OPERA 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 NOTE You can supply multiple loads as long as the total load does not exceed 4750 Peak watts or 4750 continuous watts Be sure to start the largest loads first TABLE B 2 ELECTRODE SEL
34. ing 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 The OUTBACK 145 generator power can be used to supply up to 4250 watts continuous input power to a Pro Cut 25 The Pro Cut will work satisfactorily under the fol lowing conditions 1 Set the Current Control on the OUTBACKTM 145 to the 145 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 145 has been started and is at full operating speed OUTBACK 145 x oT OPERATION 7 120V Receptacle Operation Set the Output Control on the Pro Cut 25 no higher than the 15 amp position Higher settings may cause circuit breaker on the OUTBACK 145 to trip Maximum material thickness that can be cut is 1 4 240V Receptacle Operation The Pro Cut 25 may be used for its full range of trol Maximum material thickness that can be cut is 3 8 AUXILIARY POWER OPERATION A WARNING Be sure that any electrical equipment plugged into the generator AC power receptacles can with stand a 10 voltage and a 5 frequency varia tion Some electronic devices cannot be powered by the OUTBACK 145 Refer to Table A 2 ELEC TRICAL DEVICE USE WITH THE OUTBACK 145 in t
35. ion suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE 5 POUR Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER SS TRANSFORMATEUR ET A a Utiliser un bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes x
36. 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 insulat ed 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 provid ed on the front of the welder WARNING DO NOT GROUND MACHINE TO A PIPE WHICH CARRIES EXPLOSIVE OR COMBUSTIBLE MATERIAL OUTBACK 145 INSTALLATION AP PLUGS AND HAND HELD EQUIPMENT 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 Underwriter s Laboratories UL approved double insulated tool with a two blade plug WARNING Never operate this machine with damaged defective cords All electrical equipment must be in safe operating condition AUXILIARY POWER RECEPTACLES The control panel of the OUTBACK 145 features three auxiliary power receptacles Two 20 amp 120 volt duplex double outlet receptacle A P amp 240 volt single outlet receptacle See Figure A 1 Through these receptacles the machine can supply up to 4750 watts peak or 4250 watts continuous of sin gle phase 60 Hertz AC power The machine output voltages meet UL standards and fa
37. ll within 10 of the rated voltage PREMISES WIRING The 145 is not recommended for premises wiring The OUTBACKTM 145 does not have a combined 120 240 volt receptacle and cannot be connected to a premises The OUTBACK 145 is intended only for backup intermittent power Certain electrical devices cannot be provided by the 145 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 environ ments the breakers may tend to trip at lower loads than normally NEVER BYPASS THE CIRCUIT BREAKERS WITH OUT OVERLOAD PROTECTION THE UNIT COULD OVERHEAT AND OR CAUSE DAMAGE TO THE EQUIPMENT BEING USED OUTBACK 145 7 INSTALLATION A 7 CAUTION Certain Electrical devices cannot be powered by the OUTBACKTM 145 See Table A 2 Type TABLE 2 Common Electrical Devices ELECTRICAL DEVICE USE WITH THE OUTBACK 145 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 DONOT RUN
38. ng the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 L ARC RAYS can burn 4 8 Use 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 287 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 spat
39. ompletely assembled This will help to protect you from the dangers of moving parts hot metal surfaces and live electrical devices 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 activi ties moving vehicles and other hazards 2 f 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 carbu retor 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 OUTBACK 145 m INSTALLATION 48 STACKING OUTBACK 145 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
40. prod ucts 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 54 x 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 Also see item 1 b Jan 09 SAFETY WELDING and CUTTING SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 249 1 and the operating information for the equipment being used 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 Do not heat cut or weld tanks drums or containers until the proper steps have been t
41. rpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacemen
42. s are used this welder ENGINE MAINTENANCE PARTS SUBARU ROBIN EX30 Air Filter Element Spark Plug 279 32612 08 Champion RL 86C Gap 025 65mm Resistor Type OPERATIONAL CLEARANCE CAUTION Approximately 12 18 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 OUTBACK 145 1 TROUBLESHOOTING 1 HOW 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious
43. t DC welding output for stick SMAW welding Generator The OUTBACK 145 gives smooth AC generator output for continuous auxiliary power usage within the engine manufacturer s required maintenance recom mendations OPERATIONAL FEATURES AND CONTROLS The OUTBACK 145 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 145 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 DESIGN FEATURES AND ADVANTAGES 145 amp DC constant current welding for stick electrodes e Lightweight portable Full range continuous welding output control with a single knob Hour Meter Standard Surge watts or Watts of continuous 120 240 volt single phase AC auxiliary power Subaru Robin EX30 overhead cam air cooled gasoline engine Smooth running long life WELDING CAPABILITY The OUTBACK 145 is rated at 100 amps 25VDC at 60 duty cycle on a ten minute basis This means that you can load the welder to 100 amps for six min utes out of every ten minute period The machine is capable of higher duty cycles at lower output cur rents The curr
44. t parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE 5 E UE Section A Technical SpecifiGaliOlls EE A 1 sitis Penis rat dre ee DE A 2
45. ter or metal 40 FUMES AND GASES can be dangerous 5 8 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 circum stances 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 spe cific 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 0 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
46. th to remove all excess oil Carefully place the pre cleaner back over the filter element and reinstall the air cleaner cover and wing nuts CLEAN ENGINE Remove dirt and debris with a cloth or a brush 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 SPARK PLUG SERVICE To service spark plug remove the 9 screws securing the side panel Remove side panel and place provid ed fiber spacer between the muffler and bottom of control panel See Figure D 2 FIGURE D 2 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 to be made only by a Lincoln Service Center or an authorize Field Service Shop SLIP RINGS CAUTION 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 brushes are to be replace clean slip rings with fine emery paper Do not attempt to polish slip rings while engine is running HARDWARE Both English and Metric fastener
47. the choke slightly and pull the starter cord rapidly again When the engine starts gradually open the choke to the RUN position To open the choke fully requires an engine warm up period of several seconds to sev eral minutes depending on the temperature After starting the engine first open the choke toward RUN until the engine just begins to run smoothly Then open the choke in small steps allowing the engine to accept small changes in speed and load until the choke is fully open in RUN During engine warm up the equipment can be operated FOR A HOT ENGINE Open the fuel shutoff valve Place the choke lever in the RUN position Closing the choke of a hot engine will flood the carburetor and prevent starting Pull slightly on the recoil starter handle until resistance is felt Pull the cord rapidly FOR BEST ENGINE STARTING Always use fresh gasoline and be sure the filter is clean and properly maintained If you use an alternate fuel tank or supply be sure to install an in line fuel filter elf the engine will not start see the TROU BLESHOOTING section of this or the engine owner s manual Do not pull the recoil starter with the choke in the CHOKE position more than one time Repeated pulls on a choked engine will flood the carburetor Stopping the Engine Remove all welding and auxiliary power loads and allow engine to run for a few minutes to cool the engine
48. ting 1 Troubleshooting Guide E 2 thru E 3 Wiring Diagram and Dimension Print ss Section F Parts ER 596 Series n INSTALLATION E TECHNICAL SPECIFICATIONS OUTBACKTM 145 K2707 1 INPUT GASOLINE ENGINE Make Model Description Speed RPM Displacement Ignition Capacities System SUBARU 1 cylinder 3750RPM High Idle 17 07 cu in Electric amp Recoil Fuel 6 86 gal ROBIN 4 cycle 287 cc Start 24 9L 0 air cooled B400RPM Full Load OHC gasoline Bore x Stroke Manual Oil 1 1 Qts 10 HP Choke 1 0L 3600 RPM 2 95 x 2 56 Aluminum Block 75 mm x 65mm w Cast Iron Sleeve RATED OUTPUT WELDER MAX OUTPUT OUTPUT WELDER AND GENERATOR Welding Ranges Welding Open Circuit Voltage AC Auxiliary Power 50 145 Amps DC 80 VDC Max Peak Watts 4750 Continuous Watts 4250 120 240 V 1PH PHYSICAL DIMENSIONS HEIGHT WIDTH WEIGHT 25 47 in 21 12 in 238 lbs 646 94 mm 536 45 mm 799 59 mm 107 9 kg OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 0 104 18 C TO 40 C 40 TO 131 40 TO 55 OUTBACK 145 AE INSTALLATION iis 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 mainte nance manuals supplied with your machine
49. ucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilat
50. vicing Keep away from moving parts FUMES AND GASES can be dangerous Only qualified personnel should install use or service this equipment Keep your head out of fumes Do Observe additional Safety Guidelines detailed Use ventilation or exhaust to throughout this manual remove fumes from breathing zone WELDING SPARKS can cause fire or explosion 2 Ni Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn NM Wear eye body protection OUTBACK 145 OPERATION E GRAPHIC SYMBOLS USED ON THIS EQUIPMENT OR IN THIS MANUAL WARNING CAUTION AIR CLEANER CIRCUIT BREAKER GROUND AUXILIARY POWER WORK CLAMP ELECTRODE WELDING ARC OUTBACK 145 3 OPERATION ES GENERAL DESCRIPTION The OUTBACKTM 145 is designed for commercial use welder generator applications As a welder it provides 145 amps of DC constant current for welding with DC stick electrodes A single dial lets you select a full range of welding output from 50 to 145 amps generator it can supply up to surge watts continuous watts of 120 240 volt single phase AC power The machine is portable Subaru Robin EX30 10 HP air cooled OHC gaso line engine powers the welder generator has an engine warranty of 3 years RECOMMENDED APPLICATIONS Welder The OUTBACK 145 provides excellent constant curren
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