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THEORY OF OPERATION

E-2

E-2

OUTBACK® 185

ENGINE STARTING, PROTECTION
AND BATTERY CHARGING

ENGINE STARTING

A  12  Volt  battery  supplies  power  to  the  rotary
run/stop/idle  switch  through  a  fuse  that  is  located
inside  the  control  box.    There  is  also  a  lead  running
from  the  fuse  to  the  PC  board.    This  is  for  battery
charging only.

When  the  switch  is  placed  in  the  “Low  Idle”  or  “High
Idle”  position,  a  relay  on  the  PC  board  is  activated.
This  relay  activates  the  engine  ignition  system  by
opening a ground lead from the engine magneto.

When  the  switch  is  held  in  the  “Start”  position,  the
starter  motor  solenoid  is  activated,  cranking  the
engine.  After the engine starts, the switch is released
and returns to the “high idle” position.

FIGURE E.2 - ENGINE STARTING, PROTECTION AND BATTERY CHARGING

If  the  battery  is  too  low  to  properly  power  the  starter
motor,  the  built-in  recoil  starter  can  be  used  to  crank
the engine. (As long as the battery can produce 6 volts
or  more,  the  engine  ignition  system  will  remain
enabled.)

NOTE:

This machine will only start if there is at least 6

volts available to activate the engine ignition system. If
the battery is removed or completely dead, the engine
will not start.

ENGINE PROTECTION

The Kohler engine has a built-in oil level sensor that is
connected to an oil level module.  If the oil level is low,
the ignition magneto is disabled.  This will prevent the
engine from starting, or shut it down.  Low oil level will
also  cause  a  warning  light  on  the  Outback®’s  control
panel  to  flicker  for  a  few  seconds  when  cranking  the
engine.

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

+

CB1

CB3

CB2

CB4

__

++

_ +

240 VAC

RECEPTACLE

ENGINE

OIL

LEVEL

MODULE

(KOHLER)

OIL LEVEL

INDICATOR

OIL LEVEL

SWITCH

IGNITION

STATOR

ROTOR

OFF

AUTO

HIGH

START

ALTERNATOR

IDLE

SOLENOID

SLIP

RINGS

AUXIIARY WINDINGS

WELD

WINDINGS

REACTOR

EXCITER

WINDING

CURRENT

SENSOR

120 VAC RECEPTACLES

BOOST

WINDING

OUTPUT

RECTIFIER

(2 PHASE)

CHOKE

OUTPUT

STUDS

BATTERY

ENGINE

SHUTDOWN

RELAY

HOUR

METER

FIELD / CONTROL PC BOARD

AUTOMATIC

IDLER

CIRCUIT

OUTPUT

CONTROL CIRCUIT

OUTPUT

CONTROL

10 AMP

FUSE

STARTER

/

SOLENOID

BRUSHES

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Summary of Contents for outback 185

Page 1: ...CON TAINED THROUGHOUT And most importantly think before you act and be careful SERVICE MANUAL For use with machine code number 11516 OUTBACK 185 Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 1 888 935 3877 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products Copyright Lincoln Global Inc Return to Ma...

Page 2: ...EIR 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 Co...

Page 3: ...n 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 ELECTRIC SH...

Page 4: ...ar 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 grou...

Page 5: ...ttes 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 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 l on pique le laitier 6 Eloigner les matériaux inflammables o...

Page 6: ...ce of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work com plete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The wel...

Page 7: ...d 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 electro...

Page 8: ...IONS I I OUTBACK 185 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 ...

Page 9: ...ting A 4 Lifting A 4 Pre Operation Engine Service 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 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 10: ...DTH 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 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 100 100 25 130 60 25 150 20 25 185 MAX OUTPUT Welding Ranges Welding Open Circuit Voltage AC Auxiliary Power 4600 Wa...

Page 11: ...ot 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 185 with the case roof on and all machine components completely assembled This will help to protect you from the dangers of moving parts hot metal surfaces and live electrical devices STORING 1 Store the machine in a cool ...

Page 12: ... 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 mini mum 87 octane lead free gasoline DO...

Page 13: ...r Table A 1 lists recommended cable sizes and lengths for rated current and duty cycle Length refers to the dis tance from the welder to the work and back to the welder Cable diameters are increased for long cable lengths to reduce voltage drops 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 12...

Page 14: ... 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 DO NOT GROUND MACHINE TO A PIPE WHICH CAR RIES 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 ...

Page 15: ... NEVER BYPASS THE CIRCUIT BREAKERS WITH OUT OVERLOAD PROTECTION THE UNIT COULD OVERHEAT AND OR CAUSE DAMAGE TO 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 Underwriter s Laboratories UL approved double insu lated tool with...

Page 16: ...WITHOUT ADDITIONAL RESISTIVE TYPE LOADS These devices require large current inrush for starting See Table B 3 AUXILIARY 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 An inductive type line condition er along with...

Page 17: ...nal Features and Controls B 4 Design Features and Advantages B 4 Welding Capability B 4 Limitations B 4 Controls and Settings B 5 Welder Generator Controls B 5 Engine Operation B 6 Welding Operation B 7 Auxiliary Power B 8 Electrode selection Guide B 8 Auxiliary Power Application B 9 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 18: ...ipment 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 SPARKS can cause fire or explosion Keep flammable material away Do not weld on container...

Page 19: ... OIL FUEL AIR CLEANER CIRCUIT BREAKER GROUND AUXILIARY POWER WORK CLAMP ELECTRODE WELDING ARC FAST SLOW AUTO IDLE ENGINE OFF ENGINE START Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 20: ...ngine 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 185 amp DC constant current welding for stick electrodes Lightweight portable Full range continuous welding output control with a single knob Automatic shutdown under...

Page 21: ... Provides overload protection for weld output terminals 7 CIRCUIT BREAKERS 2 Provide separate overload cur rent protection for the 120 volt and 240 volt receptacles 8 240 VOLT RECEPTACLE Connection point for supply ing 250 volt power to operate one electrical device 9 120 VOLT DUPLEX RECEPTACLES 2 Connection point for supplying 120 volt power to operate devices needed for maintenance purposes OUTP...

Page 22: ...acing the engine switch in the Off position Close the fuel valve when the machine is transported to prevent fuel leakage from the carburetor WARNING 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 E...

Page 23: ...ous 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 OUTBACK 185 to 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 WELDING OPERATION The OUTBACK 185 can deliver from 50 to...

Page 24: ...ION ELECTRODE TYPE POLARITY 3 32 SIZE 1 8 SIZE 5 32 SIZE 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 BLUE MAX 308 308L AC DC DC 50 80 75 110 95 150 ENi CI SOFTWELD 9...

Page 25: ... 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 We...

Page 26: ...NOTES B 10 B 10 OUTBACK 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 27: ...TABLE OF CONTENTS ACCESSORIES SECTION C 1 C 1 OUTBACK 185 Accessories C 1 Options Accessories C 2 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 28: ...wo wheeled hand mov able 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 c...

Page 29: ...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 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 30: ...AINTENANCE D 2 D 2 OUTBACK 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 31: ...ent 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 whichev er occurs first If the engine is operated under heavy load or in high ambient temperatures change the oil every 50 hours...

Page 32: ...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 MAINTENANCE D 4 D 4 OUTBACK 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TO...

Page 33: ...on TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1 CRADLE ASBLY BATTERY ROOF 2 CONTROL PANEL ASSEMBLY 3 STATOR ROTOR ASSEMBLY 4 REAR CONTROL PANEL FUEL TANK ASSEMBLY 5 ENGINE ASSEMBLY MAJOR COMPONENT LOCATION 1 1 5 5 4 4 2 2 3 3 ...

Page 34: ...NOTES D 6 D 6 OUTBACK 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 35: ...LEVEL INDICATOR OIL LEVEL SWITCH IGNITION STATOR ROTOR OFF AUTO HIGH START ALTERNATOR IDLE SOLENOID SLIP RINGS AUXIIARY WINDINGS WELD WINDINGS REACTOR EXCITER WINDING CURRENT SENSOR 120 VAC RECEPTACLES BOOST WINDING OUTPUT RECTIFIER 2 PHASE CHOKE OUTPUT STUDS BATTERY ENGINE SHUTDOWN RELAY HOUR METER FIELD CONTROL PC BOARD AUTOMATIC IDLER CIRCUIT OUTPUT CONTROL CIRCUIT OUTPUT CONTROL 10 AMP FUSE ST...

Page 36: ...t least 6 volts available to activate the engine ignition system If the battery is removed or completely dead the engine will not start ENGINE PROTECTION The Kohler engine has a built in oil level sensor that is connected to an oil level module If the oil level is low the ignition magneto is disabled This will prevent the engine from starting or shut it down Low oil level will also cause a warning...

Page 37: ...connected while the machine is run ning unstable voltage from the charging system will likely cause the PC board electronics to malfunction and may cause permanent damage to the PC board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to ...

Page 38: ...this and immediately interrupts the negative connection to the solenoid The solenoid is released and the engine RPM increases to the high setting When the current flow stops the PC board will begin a time delay of about 12 seconds If the current flow begins again during this time delay the solenoid remains inactive and the engine continues to operate at high RPM If no current flow is detected at t...

Page 39: ... high position all of the windings should be putting out maximum voltage almost immediately The rotor field voltage is now considerably higher than the flashing voltage that was used to start the generating process The flashing diode on the control PC board blocks that higher field voltage from intruding into the 12VDC battery system AC Output The generator is now producing normal AC power from al...

Page 40: ... output rela tive to the weld current In high welding load situations the exciter winding will tend to drop off in output while the boost winding s output tends to increase The out put from this boost winding is routed through a circuit breaker It is then rectified and added to the exciter cir cuit resulting in a significant improvement in weld per formance NOTE Unshaded areas of Block Logic Diagr...

Page 41: ...ry Charging System F 25 Stator Voltage Test F 27 Rotor Resistance and Ground Test Static F 29 Rotor Resistance and Ground Test Dynamic F 31 Stator Short Circuit and Ground F 33 Weld Boost System Test F 35 Case Cover Removal and Replacement Procedure F 37 Fuel Tank and Enclosure Removal and Replacement Procedure F 39 Control Box Removal and Replacement Procedure F 43 Stator Removal and Replacement ...

Page 42: ...liminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the specified test points components terminal strips etc can be found on the referenced ...

Page 43: ...aper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag If the PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er f...

Page 44: ...n the start position If voltage is present the starter solenoid assembly is defective contact the engine manufacturer for parts and service 3 If battery voltage is not present check the engine switch and all connectors and wires connecting the fuse switch and starter solenoid See the wiring diagram Engine will not start The starter motor will crank the engine normally 1 If using the recoil starter...

Page 45: ...good replace the PC board If the engine fails to start have the engine and oil level system checked by a qualified engine service technician The engine will not shut down 1 Place the engine switch in the stop position and check for battery voltage at the PC board pin J3 10 lead 211 If voltage is present the switch is defective 2 Locate and ground the brown white lead from the engine ignition magne...

Page 46: ...n the engine operator s manual 1 Check the idle solenoid and engine carburetor linkage for damage excessive dirt or binding If possible perform the engine RPM adjustment procedure 2 Place the engine switch in the stop position unplug engine to welder harness connector P4 J4 located inside the control box at the bottom left CAUTION Disconnecting this plug disables the normal engine shut down functi...

Page 47: ...he Auto position Check for battery voltage at the idle solenoid lead 213B if battery voltage is not present check engine switch connector P4 J4 and leads 213A and 213B 3 If battery voltage was detected in step 2 above check connector P4 J4 leads 215 and 215A 4 Check for AC voltage at leads 260 J2 3 and 261 J2 4 With no load on either the weld or auxiliary output the meter should read about 26 mV I...

Page 48: ... ohms or higher Replace the solenoid if the resistance is significantly different 2 Reconnect P4 J4 and start the machine placing the engine switch in the high position Plug in a 100 watt light bulb Check for AC voltage at leads 260 J2 3 and 261 J2 4 The meter should read about 1 2 volts If voltage is significantly lower replace the toroidal current transformer 3 If the above readings are normal r...

Page 49: ...tput or weld voltage drops dramatically when trying to strike an arc The 115 230 VAC auxiliary output is normal engine operates normally 1 Check weld cables connections work clamps and electrode holder 2 With engine running at high idle and output control set to maximum check the DC voltage at the weld output terminals It should measure 70 to 80 Volts RMS 1 Check for loose or damaged connections b...

Page 50: ...st be running at high idle RPM or the GFCI receptacles will not reset 1 Check for AC voltage at the back of the receptacles If voltage is present at the back of the receptacles but the receptacles still will not function replace the receptacle 2 Check for 120 VAC from lead 5 to leads 3 and 6 at the circuit breakers See wiring diagram If 120 VAC is present one or more circuit breakers may be defect...

Page 51: ...all button on the bottom of the control box not far from the positive weld output terminal 2 Check the weld cables electrode holder and work clamp Try welding with a known good set of short adequately sized cables 3 The battery may be low or defective 4 The welding electrode may be wet or contaminated Try using a fresh dry welding electrode 1 Perform the Engine RPM adjustment procedure 2 The brush...

Page 52: ...NOTES F 12 F 12 OUTBACK 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 53: ...irs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION Test will determine whether the engine is operating at the correct speed RPM during both HIGH and LOW idle conditions MATERIALS NEEDED Miscellaneous hand tools and metric wrench set High visibility marker Strobe tach frequency counter or vibr...

Page 54: ...ct the strobe tach light at the mark and syn chronize the strobe tach 6 The tach should read between 3700 and 3800 RPM 7 Move the idle switch to the AUTO IDLE posi tion and wait for the idle solenoid to energize The engine RPM should drop and stabilize at the low idle RPM 8 Synchronize the strobe tach to read the low idle RPM 9 The tach should read between 2250 and 2500 RPM 10 If either of the rea...

Page 55: ...eceptacles 2 Start the engine and place the idle switch in the HIGH IDLE position Make sure that there is no load on this machine 3 The frequency should read between 61 6 and 63 3 Hz 4 Move the idle switch to the AUTO IDLE posi tion and wait for the idle solenoid to energize The engine RPM should drop and stabilize at the low idle RPM 5 The frequency should read between 47 5 and 41 6 Hz 6 If eithe...

Page 56: ...s no load on the machine 3 Position and adjust the Vibratach is should read between 3700 and 3800 RPM 4 Move the idle switch to the AUTO IDLE posi tion and wait for the idle solenoid to energize and the engine RPM to drop and stabilize at the low idle RPM 5 Position and adjust the Vibratach it should read between 2250 and 2500 RPM 6 If either of the readings is incorrect proceed to the Throttle Ad...

Page 57: ...ot understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the adjustment of the throttle MATERIALS NEEDED Flathead Screw THROTTLE ADJUSTMENT PROCEDURE TROUBLESHOOTING AND REPAIR F 17 F 1...

Page 58: ...re F 4 Turning the screw clockwise will increase RPM and turning it counterclockwise will decrease the RPM Engine high idle RPM should be between 3700 and 3800 RPM Low Idle Adjustment 1 With engine running and no load applied to the machine place the engine switch in the AUTO IDLE position Wait for the idle solenoid to energize and the engine speed to drop and sta bilize at low idle RPM 2 If the l...

Page 59: ...he test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 PROCEDURE DESCRIPTION This procedure provides guidance in testing and maintaining the brush and slip ring sys tem MATERIALS NEEDED 500 or 600 grit emery cloth 220 or 320 grit commutator stone Optional Needlenose Pliers 1 4 Nut Driver BRUSH AND SLI...

Page 60: ...making good continuous contact with the slip rings 6 The brushes should be of sufficient length and have adequate spring tension Generally the brushes should be replaced if either brush has less than 1 4 remaining before it reaches the end of its travel Spring tension should be suf ficient to hold the brushes firmly against the slip rings 7 The brushes should be removed from the brush holder and b...

Page 61: ...irty discolored or mildly pitted it will become necessary to clean them using very fine 500 or 600 grit emery cloth or a 220 or 320 grit com mutator stone 2 Use low pressure compressed air to thoroughly blow the carbon commutator stone and sand paper dust from the machine before operating 3 To install the brush holder assembly push the brushes into the brush holder assembly and place a plastic cab...

Page 62: ...NOTES F 22 F 22 OUTBACK 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 63: ... the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if correct voltage is being applied to the rotor slip rings MATERIALS NEEDED Misc hand tools Multimeter ROTOR FLASHING AND VOLTAGE TEST TROUBLESHOOTING AND RE...

Page 64: ...ero or near zero per form the Rotor Resistance Test 9 Check for battery voltage at lead 224 J1 9 Check that the PC board is properly grounded at lead GND G J1 2 If the board is getting battery voltage and is properly grounded replace the board 10 If the voltage reading is about 3 to 5 volts DC check for AC voltage between Lead 7 Terminal B2 and Lead 9 Terminal B1 If the voltage is about the same o...

Page 65: ...are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the battery charging system is functioning properly MATERIALS NEEDED Misc hand tools Multimeter Jumper lead with a 10 amp inline fuse or circuit breaker BATTERY CHARGING SYSTEM TE...

Page 66: ...condition and is securely connected 2 Start the engine and test the voltage at the bat tery terminals The meter should read between 13 5 and 14 5 volts DC 3 If the voltage is low shut off the engine 4 Disconnect lead 208 from the engine alterna tor and place a fused jumper lead between the alternator and the positive battery terminal See Figure F 8 See wiring diagram 5 Start the engine and check v...

Page 67: ...contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test determines if the stator is producing the correct voltage from each of the wind ings This test should be performed if rotor voltage is normal but one or more of the out put voltage readings are incorrect MATERIALS NEEDED Miscellaneous hand too...

Page 68: ...agram 4 Check for AC voltage between leads W1 and W2 See Wiring Diagram Voltage reading should be about 64 VAC Also check for AC voltage between leads W3 and W4 Voltage reading should be about 62 VAC See wiring digram 5 If the voltage is not present or is significantly dif ferent from expected readings check the wiring between test points and the stator winding See wiring diagram If the wiring is ...

Page 69: ... perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the rotor winding is open shorted or grounded MATERIALS NEEDED Miscellaneous hand tools Ohmmeter analog type meter required for dynamic resistance test Wiring Diagram ROTOR RESISTANCE AND GROU...

Page 70: ...sure the resistance to ground Place one meter probe on either of the slip rings Place the other probe on any good unpainted chassis ground The resistance should be very high at least 500 000 500k ohms 7 If the test does not meet the resistance specifi cations then the rotor may be faulty and should be replaced 8 If this test meets resistance specifications con tinue testing using the Dynamic Rotor...

Page 71: ...stand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will aid the technician in checking for faults in the rotor winding MATERIALS NEEDED Analog Ohmmeter ROTOR RESISTANCE AND GROUND TEST DYNAMIC TROUBLESHOOTING AND REPAIR...

Page 72: ... F 11 5 Start the engine and run it at high idle speed The resistance should read approximately 9 ohms at 77 F 25 C 6 Shut off engine and move one of the ohmmeter leads to a good clean chassis ground connec tion 7 Restart the engine and run it at high idle speed The resistance should be very high at least 500 000 500k ohms 8 If the resistance readings differ significantly from the values indicated...

Page 73: ...t for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if there are undesirable electrical connections between the stator windings and chassis ground or between individual windings within the stator This test should be performed if flashing voltage is present at the rotor slip rings but the voltage output on leads 7 and 9 is to...

Page 74: ...it connections between the windings that should be isolated from each other 8 Using an ohmmeter check the resistance between the following points Resistance should red very high 500 000 500k ohms min imum a The 5 lead that had been disconnected from the neutral stud and either lead 7 or lead 9 This checks for a connection between the auxiliary power winding and the excited winding b The 5 lead tha...

Page 75: ...pairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test checks the functionality of the weld boost system This test should be done if the weld terminal open circuit voltage and engine RPM are normal but the machine weld output is low MATERIALS NEEDED Resistive load bank Misc hand tools...

Page 76: ... Cover Removal Procedure 10 Start the engine and apply a load of about 80 to 100 Amps 11 Check for AC voltage between leads 13 and 14 at the PC board See wiring diagram 12 If voltage is present rotate the output control knob and observe the voltage between leads 13 and 14 The voltage should rise and fall as the output control is moved 13 If the voltage at leads 13 and 14 is responding as described...

Page 77: ...est procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the case sheet metal covers MATERIALS NEEDED 3 8 Wrench CASE COVER REMOVAL AND REPLACEMENT PROCEDURE TROUBLESHOOTING...

Page 78: ...ws from the top of the red sheet metal cover 2 Lift the top cover off of the machine 3 To replace the cover reverse the above proce dure TROUBLESHOOTING AND REPAIR F 38 F 38 OUTBACK 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 79: ...form the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the fuel tank enclosure MATERIALS NEEDED Approved gasoline container and pump 7 16 Wrench Rags Pliers 3 8 Wrench FUEL TANK AND ENCLOSURE REMOVAL AND RE...

Page 80: ...her sources of ignition 1 Perform the Case Cover Removal Procedure 2 Close gasoline valve Red Lever located on bottom of gas tank 3 Using a 7 16 wrench disconnect the negative battery cable See Figure F 15 Note washer placement label and disconnect for reassem bly 4 Pump gasoline into an approved gasoline con tainer 5 Using pliers remove fuel line clamp located on gasoline valve 6 Carefully remove...

Page 81: ...CLOSURE REMOVAL AND REPLACEMENT PROCEDURE continued TROUBLESHOOTING AND REPAIR F 41 F 41 OUTBACK 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 82: ...NOTES F 42 F 42 OUTBACK 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 83: ...est repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the control box MATERIALS NEEDED Cable Ties Wire Marking Supplies Wiring Diagram Phillips Screwdriver 3 8 Wrench 7 16 Wrench Needle Nose Pliers CONTROL BOX REMOV...

Page 84: ...e mounting 8 Using pliers remove choke cable from engine 9 Using the wiring diagram identify all of the wires wire splices and plugs that connect con trol box components to the engine and genera tor If any wire or connector is not clearly marked mark them so they can be properly reconnected It is also helpful to make notes as needed 10 Cut cable ties as needed and disconnect these wires 11 Remove ...

Page 85: ...X REMOVAL AND REPLACEMENT PROCEDURE continued TROUBLESHOOTING AND REPAIR F 45 F 45 OUTBACK 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 86: ...NOTES F 46 F 46 OUTBACK 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 87: ...he test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the stator MATERIALS NEEDED 1 2 Wrench 7 16 Wrench Hoist STATOR REMOVAL AND REPLACEMENT PROCEDURE TROUBLESHOOTING AND...

Page 88: ...for reassembly See Figure F 19 5 Use a hoist or get a helper and lift the engine and generator assembly out of the tubular steel frame Place the engine and generator assem bly on a strong solid work surface 6 Using a 7 16 wrench remove the four bolts connecting the cast stator brackets Note the precise position of all hardware components and washers Using a plastic hammer gently and evenly tap out...

Page 89: ...ll a new tolerance ring 5 Place the brush end bracket over the stator Use a plastic or rubber hammer to tap the bracket in place 6 Adjust the stator and brackets as needed and install the stator through bolts placing the hard ware components the same as they were before removal 7 Place the engine and generator assembly into the tubular frame of the machine and loosely install the rubber mount fast...

Page 90: ... to pass completely through the air gap and a 030 gage should not penetrate the air gap any far ther than any tapered portion on the end of the gage 11 Reinstall the control box and fuel tank previ ously removed 12 Replace the case wraparound cover TROUBLESHOOTING AND REPAIR F 50 F 50 OUTBACK 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Mast...

Page 91: ... are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the rotor MATERIALS NEEDED Rotor Puller Tool See parts pages for the tool part number Impact Wrench ROTOR REMOVAL AND REPLACEMENT PROCEDUR...

Page 92: ... If necessary the cast end bracket can now be removed from the engine Replacing the Rotor 1 If the cast end bracket had been removed from the engine clean the mating surfaces and rein stall it on the engine at this time Bolts should be tightened to a torque of 22 to 24 ft lbs It is highly recommended that a new bearing be installed before the rotor is secured to the engine crankshaft 2 Thoroughly ...

Page 93: ...nal open Circuit Voltage OCV Weld control at maximum 70 80 VDC Weld control at minimum 45 60 VDC Full load test values Weld output control set to maximum Output amps 165 190 Volts 21 27 RPM 3300 3650 Weld output set to minimum Output amps 40 55 Volts 20 28 Auxiliary receptacles with weld output control set to maximum 230 Volt receptacles Load amps 22 25 Volts 216 250 VAC 120 Volt receptacles Load ...

Page 94: ...NOTES F 54 F 54 OUTBACK 185 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 95: ...e Code 11516 G6205 G 3 Schematic Field Control Idle PC Board G4793 1 G 4 NOTE Many PC Board Assemblies are now totally encapsulated surface mounted and or multi lay ered and are therefore considered to be unserviceable Assembly drawings of these boards are no longer provided Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 96: ... EL B CB4 5A D1 HOUR METER LOW OIL INDICATOR L E D 210A BW YR 210B ELEC L13878PRINT A WIRING DIAGRAM OUTBACK 185 14 TOP BOTTOM 13A 2ND 1ST BOTTOM 4TH TOP 3RD P4 224A 208A 75 211 240 V SILVER SILVER 6B GND G GND K GND NEUTRAL STUD ON CONTROL PANEL BOTTOM 5B 5B 5A 5A 5 GND C GND E GROUND STUD ON CONTROL PANEL FRONT GND C WRAP IN OPPOSITE DIRECTIONS 3 GND D 3B 3A 11 GND F 12 6B 6A CB1 30A CB3 20A CB2...

Page 97: ... fromKohler Engine muffleris located in the middle RIGHT side area Engine oil fill check drain LEFT or RIGHTsides low on engine The black oil cover is fill the gray one has a dip stick on it Bolt in casting is drain plug Spark plugs are resistor type Battery or Pull start Pull is done from the left rear side engine Engine is a KohlerCS12 75 aluminum block w case iron sleeve 12 75HP 3600RPM Air Coo...

Page 98: ...ROUND CONNECTION UNLESS OTHERWISE SPECIFIED COMMON CONNECTION FRAME CONNECTION SUPPLY VOLTAGE NET LABELS 022 50V 1 4W 1A 400V HAVING A COMMON CODE NUMBER COMPONENTS OR CIRCUITRY OF CONTROLS DIAGRAM MAY NOT SHOW THE EXACT ABILITY OF A COMPLETE BOARD THIS WITHOUT AFFECTING THE INTERCHANGE PRINTED CIRCUIT BOARD MAY CHANGE SINCE COMPONENTS OR CIRCUITRY ON A G REFERENCE 5 1K 5W R1 12VDC 1 2 CR1 4 3 5 C...

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