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Lincoln Electric OUTBACK 145 Service Manual
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Lincoln Electric OUTBACK 145 Service Manual

Lincoln Electric OUTBACK 145 Service Manual

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®
OUTBACK
145
For use with machines having Code Numbers:
11517 & 11732
SERVICE MANUAL
SVM216-A
| Issue D ate 12-Jan
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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Summary of Contents for Lincoln Electric OUTBACK 145

  • Page 1 NOTE: This manual will cover most of the troubleshooting and repair procedures for the code numbers listed. Some variances may exist when troubleshooting/repairing later code numbers. ® OUTBACK For use with machines having Code Numbers: 11517 & 11732 SERVICE MANUAL Need Help? Call 1.888.935.3877 to talk to a Service Representative Hours of Operation:...
  • Page 2 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.
  • Page 3 SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 4.a. Use a shield with the proper fi lter and cover 3.a. The electrode and work (or ground) circuits plates to protect your eyes from sparks and are electrically “hot” when the welder is on. the rays of the arc when welding or observing Do not touch these “hot”...
  • Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fi re or if damaged. 7.a. Use only compressed cylinders explosion. containing the correct shielding gas for the 6.a. Remove fi re hazards from the welding area. process used properly operating If this is not possible, cover them to prevent the regulators designed for the gas and...
  • Page 5 SAFETY prévenir tout risque d’incendie dû aux étincelles. PRÉCAUTIONS DE SÛRETÉ 7. Quand on ne soude pas, poser la pince à une endroit isolé Pour votre propre protection lire et observer toutes les instructions et de la masse. Un court-circuit accidental peut provoquer un les précautions de sûreté...
  • Page 6 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
  • Page 7 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommen- dations.
  • Page 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ..................i-vi Installation, Operation, Accessories, Maintenance .
  • Page 9 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 Block Logic Diagram .
  • Page 10 fi eld feedback winding. The fi eld feedback winding provides rotor current during machine operation. The output of the Outback 145 is dependent on two criteria: the engine RPM and the amount of current in the rotor winding.
  • Page 11 THEORY OF OPERATION FIGURE E.3 - ROTOR FIELD FEEDBACK AND AUXILIARY POWER CHOKE OUTPUT TERMINALS RECTIFIER BRIDGE STATOR ENGINE MECHANICAL ROTATION ROTOR ROTOR SLIP RINGS MAGNETO CIRCUIT STATOR CAPACITOR LOW OIL SWITCH CIRCUIT CIRCUIT BREAKER BREAKER RUN/STOP SWITCH RHEOSTAT BRIDGE 230 VAC 115 VAC RECEPTACLES...
  • Page 12 The weld winding provides AC current to the full wave bridge and is rectifi ed to DC which is then fi ltered The Outback 145’s 4250 watt auxiliary power winding through the choke coil to provide up to 145 amps of and circuitry is protected from an overload condition by stick welding current.
  • Page 13 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. . F-1 How to Use Troubleshooting Guide .
  • Page 14 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 15 Do not touch electrically hot parts. - 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- CAUTION er failure analysis.
  • Page 16 6. Perform the Field Diode Bridge Test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. OUTBACK ®...
  • Page 17 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. OUTBACK ®...
  • Page 18 See Wiring Diagram. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. OUTBACK...
  • Page 19 See Wiring Diagram. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. OUTBACK...
  • Page 20 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. OUTBACK ®...
  • Page 21 (L1). CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. OUTBACK...
  • Page 22 F-10 NOTES F-10 OUTBACK ®...
  • Page 23 ROTOR VOLTAGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 24 F-12 TROUBLESHOOTING AND REPAIR F-12 ROTOR VOLTAGE TEST (continued) FIGURE F.1 – LOCATION OF LEAD 202 FOR ROTOR VOLTAGE TEST GROUND STUD LEAD 202 CONNECTION (TOP TERMINAL, CASE FRONT IN PLACE PROCEDURE 1. With the 3/8” nut driver, remove the 20 sheet 5.
  • Page 25 ROTOR RESISTANCE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 26 F-14 TROUBLESHOOTING AND REPAIR F-14 ROTOR RESISTANCE TEST (continued) FIGURE F.2 – LOCATION OF ROTOR SLIP RINGS - BRUSH HOLDER ASSEMBLY REMOVED SLIP RINGS PROCEDURE 1. Conduct the test with the gasoline engine OFF. 7. Measure the resistance across the rotor slip rings.
  • Page 27 F-15 TROUBLESHOOTING AND REPAIR F-15 ROTOR RESISTANCE TEST (continued) FIGURE F.3 – BRUSHES RETAINED WITH CABLE TIE CABLE BRUSHES 9. Reinstall the brush holder assembly after the test. Depress the spring-loaded brushes into the holder and slip a suitable non-metallic, fairly stiff retainer through the slots at the top and bot- tom of the holder.
  • Page 28 F-16 NOTES F-16 OUTBACK ®...
  • Page 29 ROTOR “FLASHING” CIRCUIT TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 30 F-18 TROUBLESHOOTING AND REPAIR F-18 ROTOR “FLASHING” CIRCUIT TEST (continued) FIGURE F.4 – BRUSH HOLDER LEADS 201A(-) AND 202B(+) 201A(-) 202B(+) Slip Rings PROCEDURE 1. With the 3/8” nutdriver, remove the 20 sheet 3. Connect the negative (-) lead of the DC amme- metal screws that hold the top cover to the con- ter to lead #201A and the positive (+) lead to trol box.
  • Page 31 F-19 TROUBLESHOOTING AND REPAIR F-19 ROTOR “FLASHING” CIRCUIT TEST (continued) WARNING MOVING PARTS can injure. Keep away from moving parts. ENGINE EXHAUST can kill. Use in open, well ventilated areas or vent exhaust to the outside. 5. Start the engine and run it at High Idle (3700 - 3800 RPM).
  • Page 32 F-20 NOTES F-20 OUTBACK ®...
  • Page 33 OUTPUT RECTIFIER BRIDGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 34 F-22 TROUBLESHOOTING AND REPAIR F-22 OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.6 – OUTPUT RECTIFIER BRIDGE POSITIVE NEGATIVE TERMINAL TERMINAL AC INPUT PROCEDURE 1. Remove the 20 bolts holding down the control box cover by using a 3/8” nutdriver. Remove cover.
  • Page 35 ROBIN / SUBARU ENGINE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 36 F-24 TROUBLESHOOTING AND REPAIR F-24 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.7 – MARK LOCATION MARK PROCEDURE Frequency Counter Method: 1. Plug the frequency counter into one of the 115 This test can be conducted by any of three meth- VAC auxiliary receptacle.
  • Page 37 F-25 TROUBLESHOOTING AND REPAIR F-25 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.8 – LOCKING NUT LOCATION THROTTLE LOCKING 2. Using the 10mm socket wrench, slightly loosen the throttle locking nut. See Figure F.8. 3. Using the screwdriver, adjust the high speed stop screw until the waveform period is 16.2 milliseconds.
  • Page 38 F-26 NOTES F-26 OUTBACK ®...
  • Page 39 FIELD DIODE BRIDGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 40 F-28 TROUBLESHOOTING AND REPAIR F-28 FIELD DIODE BRIDGE TEST (continued) FIGURE F.10 – DOOR REMOVAL POSITIVE DC SINGLE PHASE BRIDGE CIRCUIT CONFIGURATION NEGATIVE DC PROCEDURE The diode bridge is confi gured as pictured above. The individual diodes can be tested using a diode tester or an ohmmeter.
  • Page 41 F-29 TROUBLESHOOTING AND REPAIR F-29 NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 0 volts This is the typical output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.
  • Page 42 F-30 TROUBLESHOOTING AND REPAIR F-30 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY) HIGH IDLE – NO LOAD 1 Period = 16.2 ms @ 3700 rpm 0 volts This is the typical auxiliary output volt- age generated from a properly operat- ing machine.
  • Page 43 F-31 TROUBLESHOOTING AND REPAIR F-31 TYPICAL WELD OUTPUT WAVEFORM MACHINE LOADED 0 volts 20 volts This is the typical auxiliary output volt- age generated from a properly operat- ing machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time.
  • Page 44 F-32 TROUBLESHOOTING AND REPAIR F-32 ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 0 volts 50 volts This is not the typical DC output voltage waveform. Note the “gap” in the waveform. One output diode was disconnected to simulate an “open”...
  • Page 45 BRUSH REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 46 F-34 TROUBLESHOOTING AND REPAIR F-34 BRUSH REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.11 – BRUSHES RETAINED WITH CABLE TIE CABLE BRUSHES PROCEDURE 1. Remove the spark plug wire. 5. To change the brushes, use the slot head screwdriver to pop off the plastic retainer on the 2.
  • Page 47 F-35 TROUBLESHOOTING AND REPAIR F-35 BRUSH REMOVAL AND REPLACEMENT PROCEDURE (continued) 8. To reinstall the brush holder assembly, depress 11. Reinstall and tighten the 2 screws with the 1/4” the spring-loaded brushes into the holder and nut driver. slip a suitable non-metallic, fairly stiff retainer 12.
  • Page 48 F-36 NOTES F-36 OUTBACK ®...
  • Page 49 RHEOSTAT REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 50 F-38 TROUBLESHOOTING AND REPAIR F-38 RHEOSTAT REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.12 – RHEOSTAT REMOVAL PROCEDURE 1. Remove the spark plug wire. 7. To reinstall the rheostat, replace each of the brass screws. Place a shake-proof star washer 2. With the 3/8” nut driver, remove the 20 sheet under the head, insert the screw into the rheo- metal screws that hold the top cover to the con- stat and tighten down one nut.
  • Page 51 STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 52 F-40 TROUBLESHOOTING AND REPAIR F-40 STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.13 – GENERATOR AND ENGINE LOCATION ENGINE GENERATOR PROCEDURE 1. Remove control panel cover by removing the 20 screws with a 3/8” nutdriver. 2. Remove the right case side by removing the 5 screws using a 3/8”...
  • Page 53 F-41 TROUBLESHOOTING AND REPAIR F-41 STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.14 – GENERATOR COMPONENTS ROTOR THRU BOLT BRUSH ASSEMBLY STATOR LAMINATION ASSEMBLY END BRACKET BEARING BRACKET MACHINING END COVER 6. Remove the brush assembly from the slip ring end bracket.
  • Page 54 F-42 TROUBLESHOOTING AND REPAIR F-42 STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) 12. If impact wrench is available, rapidly torque impact bolt until rotor “pops” off of tapered engine crank. If impact wrench is unavailable, restrain rotor and tighten bolt with socket wrench until rotor “pops”...
  • Page 55 F-43 TROUBLESHOOTING AND REPAIR F-43 RETEST AFTER REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine’s electrical characteristics. • If you repair or replace any electrical components. ENGINE OUTPUT No Load RPM Load RPM...
  • Page 56 F-44 NOTES F-44 OUTBACK ®...
  • Page 57 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram (L13929) (Code 11517) .
  • Page 58 ElECTriCal DiaGramS WiriNG DiaGram - (l13929) WIRING DIAGRAM - OUTBACK 145 ROTOR FIELD 200C 202C 202A 200A 100 W HOUR SLIP METER OUTPUT 202B RHEOSTAT 600 µFD RINGS 201C 201B 201D 201A GND-C GND-F GROUND STUD ON GENERATOR CONTROL PANEL FRONT...
  • Page 59 TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 SCALE: CLEVELAND CONTROL: EQUIPMENT TYPE: OUTBACK 145 UNLESS OTHERWISE SPECIFIED TOLERANCE: PAGE ___ OF ___ NONE ON 2 PLACE DECIMALS IS ± .02 in. ( ± 0.5 mm) DRAWN BY: mpatrzyk ON 3 PLACE DECIMALS IS ±...

This manual is also suitable for:

1151711732