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Lincoln Electric OUTBACK 145 IM973, Operator'S Manual

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Lincoln Electric OUTBACK 145 IM973 Operator'S Manual Download Page 7

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TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications .......................................................................................................A-1
Safety Precautions. ..............................................................................................................A-2

Location and Ventilation ................................................................................................A-2
Storing ...........................................................................................................................A-2
Stacking ........................................................................................................................A-3
Tilting.............................................................................................................................A-3
Lifting.............................................................................................................................A-3

Pre-Operation Engine Service..............................................................................................A-3

Oil ..................................................................................................................................A-3
Fuel ...............................................................................................................................A-3
Spark Arrester ...............................................................................................................A-3

Electrical and Welding Connections .....................................................................................A-4

Machine Grounding .......................................................................................................A-5

Plugs and Hand-Held Equipment, Auxiliary Power Receptacles .........................................A-6
Premises Wiring ...................................................................................................................A-6
Circuit Breakers ....................................................................................................................A-6
Electrical Devices used with the OUTBACK™ 145 ..............................................................A-7

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Operation.........................................................................................................................Section B

Safety Instructions ................................................................................................................B-1
Symbols................................................................................................................................B-2
General Description..............................................................................................................B-3
Recommended Applications.................................................................................................B-3
Operational Features and Controls ......................................................................................B-3
Design Features and Advantages ........................................................................................B-3
Welding Capability................................................................................................................B-3
Limitations ............................................................................................................................B-3
Controls and Settings ...........................................................................................................B-4
Welder/Generator Controls ..................................................................................................B-4
Engine Operation .................................................................................................................B-5
Welding Operation................................................................................................................B-6
Auxiliary Power.....................................................................................................................B-7

Electrode selection Guide .............................................................................................B-7

Auxiliary Power Application ..................................................................................................B-8

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Accessories .....................................................................................................Section C

General Options / Accessories ..............................................................................C-1

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Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1
Routine and Periodic Engine Maintenance....................................................D-1, D-2

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Troubleshooting ..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-3

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Wiring Diagram and Dimension Print ............................................................Section F

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Parts List ....................................................................................................P-596  Series

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Summary of Contents for OUTBACK 145 IM973

Page 1: ...lt with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPER ATE OR REPAIR THIS EQUIP MENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 11517 Copyright Lincoln Global Inc This manua...

Page 2: ...MAKER 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 av...

Page 3: ...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 FUMES AND GASES can be dangerous 5 a Welding may produce f...

Page 4: ...gs to adjacent 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...

Page 5: ...priés et non inflammables 4 Des gouttes de laitier en fusion sont émises de lʼarc de soudage Se protéger avec des vêtements de protection libres de lʼhuile tels que les gants en cuir chemise épaisse pan talons 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 lʼon pique le laitier 6 El...

Page 6: ...y 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 li...

Page 7: ...mitations B 3 Controls and Settings B 4 Welder Generator Controls B 4 Engine Operation B 5 Welding Operation B 6 Auxiliary Power B 7 Electrode selection Guide B 7 Auxiliary Power Application B 8 ________________________________________________________________________________ Accessories Section C General Options Accessories C 1 ______________________________________________________________________...

Page 8: ...um Block 75 mm x 65mm w Cast Iron Sleeve INPUT GASOLINE ENGINE RATED OUTPUT WELDER HEIGHT WIDTH DEPTH WEIGHT 25 47 in 21 12 in 31 48 in 238 lbs 646 94 mm 536 45 mm 799 59 mm 107 9 kg 0 F TO 104 F 18 C TO 40 C 40 F TO 131 F 40 C TO 55 C OUTPUT WELDER AND GENERATOR OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE AMPS DC CONSTANT CURRENT DUTY CYCLE VOLTS RATED AMPERES 80 100 25 100 60 25 125 30...

Page 9: ...aust is ventilated to an open outside area The OUTBACK 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 completely assembled This will help to protect you from the dangers of moving parts ...

Page 10: ...e 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 145 capacity is approx imately 6 8 gallons 25 74...

Page 11: ...r 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 TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Length 0 50 ft 0 15m 50 100 ft 15 30 m 100 150 ft 30 46 m 150 200 ft 46 61 m 200 250 ft 61 76m 125 Amps 30 Duty Cycle 6 AWG 5 AWG 3 AWG 2 AWG 1 AWG TABLE ...

Page 12: ... equipment A machine grounding stud marked with the symbol is provid ed on the front of the welder DO NOT GROUND MACHINE TO A PIPE WHICH CARRIES EXPLOSIVE OR COMBUSTIBLE MATERIAL WARNING 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 Electr...

Page 13: ...O THE EQUIPMENT BEING USED CAUTION 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 Underwriterʼs Laboratories UL approved double insulated tool with a two blade plug Never operate this machine with damaged or defective cords All electrical equipment must be ...

Page 14: ...ulation can cause the capac itative elements to fail Surge protection transient protection and additional loading is recom mended for 100 fail safe opera tion DO NOT RUN THESE DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS These devices require large current inrush for starting See Table B 3 GENERATOR POWER APPLICATIONS in the OPERA TION section of this manual for required starting wattages Some ...

Page 15: ...away from moving parts Only qualified personnel should install use or service this equipment 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 WELDING SP...

Page 16: ...B 2 OPERATION B 2 OUTBACK 145 GRAPHIC SYMBOLS USED ON THIS EQUIPMENT OR IN THIS MANUAL WARNING CAUTION CHOKE OIL FUEL AIR CLEANER CIRCUIT BREAKER GROUND AUXILIARY POWER WORK CLAMP ELECTRODE WELDING ARC ...

Page 17: ...ols 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 Lightweight portable Full range continuous welding output control with a single knob Hour Meter Standard Surge watts or ...

Page 18: ...s 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 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 Pro...

Page 19: ...u use an alternate fuel tank or supply be sure to install an in line fuel filter 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 If the engine will not start see the TROU BLESHOOTING section of this or the engine ownerʼs manual Stopping the Engine Remove all welding and auxiliary power loads and allo...

Page 20: ...ing conditions 1 Set the Current Control on the OUTBACK 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 WELDING OPERATION The OUTBACK 145 can deliver from 50 to 145 amps of welding output current Output can be adjusted by setting the current cont...

Page 21: ...C 50 75 75 135 E6011 FLEETWELD 35 DC 50 75 70 110 80 125 E6011 FLEETWELD 180 DC 50 80 55 110 105 125 E6013 FLEETWELD 37 DC 70 95 100 135 E7018 EXCALIBUR 7018 DC 70 100 90 125 125 145 E7018 JETWELD LH 73 DC 65 85 90 125 E708 17 E308L 17 BLUE MAX 308 308L AC DC DC 50 80 75 110 80 125 ENi CI SOFTWELD 99Ni DC 50 80 80 110 WEARSHIELD ABR DC 50 150 1 8 AND SHEET THICKNESS THINNER 1 8 AND THICKER recepta...

Page 22: ...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 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 ...

Page 23: ...f 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 bolts for removing the generator rotor from ta...

Page 24: ...tion and operating conditions The Subaru Robin Ownerʼs 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 operating conditions change the oil after every 100 hours or once a year whichever occurs first If the eng...

Page 25: ... this machine is 3750 RPM no load Do NOT tamper with the governor components or setting or make any other adjustments to increase the maximum speed Severe personal injury and damage to the machine can result if operated at speeds above maximum Adjustments to the engine are to be made only by a Lincoln Service Center or an authorize Field Service Shop ENGINE MAINTENANCE PARTS SUBARU ROBIN EX30 Air ...

Page 26: ...LE CAUSE lists the obvious 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 Authori...

Page 27: ...Facility 1 Check brushes for wear See Maintenance section 2 Check for loose or faulty connections at brush holders 3 Open lead in flashing or field circuit 4 Rheostat R1 lead broke 5 Dirty slip rings 6 Faulty rheostat R1 7 Faulty field bridge rectifier D1 8 Faulty field capacitor C1 9 Faulty stator field winding 10 Faulty rotor 1 Loose connector to output stud 2 Work not connected 3 Electrode hold...

Page 28: ... oil level 1 Water in engine from rain and or condensation Remove spark plug and dry it if wet Blow low pressure compressed air in spark plug port while pulling recoil starter Re install spark plug 2 Spark plug may be faulty 3 Air filter element saturated with water and or oil Replace 1 Engine is not fully warmed up and engine choke is in the fully open RUN position 2 Engine requires service to he...

Page 29: ... may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 30: ...F 2 DIMENSION PRINT F 2 OUTBACK 145 M21768 A 02 6 75 29 00 31 47 NOTES N A CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK N A 25 62 21 60 7 79 13 50 8 25 ...

Page 31: ...NOTES OUTBACK 145 ...

Page 32: ... und Entlüftung des Arbeitsplatzes G Mantenha seu rosto da fumaça G Use ventilação e exhaustão para remover fumo da zona respiratória G Turn power off before servicing G Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio G Débranchez le courant avant l entre tien G Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten G Não o...

Page 33: ...parts or electrode with skin or wet clothing G Insulate yourself from work and ground G No toque las partes o los electrodos bajo carga con la piel o ropa moja da G Aislese del trabajo y de la tierra G Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension G Isolez vous du travail et de la terre G Berühren Sie keine stromführenden Teile oder Elektroden mit ...

Page 34: ...s 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 World s Leader in Welding and Cutting Products ...

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