SVM 113-A View Safety Info January, 1996 TM WELDANPOWER 125 For use with machine code numbers 10158 and 10160 Return to Master TOC View Safety Info View Safety Info Safety Depends on You Return to Master TOC Return to Master TOC RETURN TO MAIN INDEX Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation . . . and thoughtful operation on your part.
Return to Master TOC i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
Return to Master TOC Return to Master TOC ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.
Return to Master TOC iii SAFETY WELDING SPARKS can 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. 6.b.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v RETURN TO MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety.................................................................................................................................................i-iv Installation .............................................................................................................................Section A Technical Specifications .............................................................................................................
Return to Master TOC Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Installation Technical Specifications .............................................................................................................A-2 Safety Precautions......................................................................................................................A-3 Location and Ventilation ........................................................................................................
Return to Master TOC A-2 INSTALLATION TECHNICAL SPECIFICATIONS - WELDANPOWER 125 INPUT - GASOLINE ENGINE Manufacturer Description Briggs & Stratton Vanguard® Return to Master TOC Return to Section TOC Return to Section TOC A-2 1 cyl., 4 cycle air-cooled gasoline 9 HP @ 3600 RPM Speed Displacement Ignition Capacities 3400 RPM Full Load 3750 RPM High Idle 2400 RPM Low Idle 18.06 cu. in. (296 cc) Manual, Recoil start; Manual choke Fuel: 1.6 gal. (6.0 l) Oil: 1.25 qt. (1.
Return to Master TOC INSTALLATION Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and maintenance instructions; and parts lists. Return to Master TOC Return to Section TOC Return to Section TOC A-3 ELECTRIC SHOCK can kill.
Return to Master TOC Return to Section TOC A-4 INSTALLATION STACKING OIL WELDANPOWER 125 machines CANNOT be stacked. The WELDANPOWER 125 is shipped with the engine filled with SAE 10W-30 oil. CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE. This is an added precaution. Do not screw in the dipstick when checking the oil. If it is not full, add enough oil to fill it. DO NOT OVERFILL. Be sure the fill plug is tight. TILTING Place the machine on a secure, level surface whenever you use it or store it.
Return to Master TOC Return to Section TOC A-5 A-5 INSTALLATION FIGURE A.1 - WELDANPOWER 125 OUTPUT CONNECTIONS 1 Return to Master TOC Return to Section TOC 6 5 3 2 Return to Master TOC Return to Section TOC 1. CURRENT CONTROL DIAL 2. WELD OUTPUT TERMINALS (2) 3. GROUND STUD 4. CIRCUIT BREAKERS (2) - 20 AMP (15 AMP CSA) 5. RECEPTACLE - 230 VOLT, 20 AMP (15 AMP CSA) 6. DUPLEX RECEPTACLE - 115 VOLT, 20 AMP (15 AMP CSA) ELECTRICAL OUTPUT CONNECTIONS See Figure A.
Return to Master TOC Return to Section TOC A-6 INSTALLATION Cable Installation WARNING Install the welding cables to your WELDANPOWER 125 as follows. See Figure A.1 for the location of parts. 1. The gasoline engine must be OFF to install welding cables. 2. Remove the 1/2 - 13 flanged nuts from the output terminals. 3. Connect the electrode holder and work cables to the weld output terminals. Normally, the electrode cable is connected to the positive (+) output terminal. Return to Master TOC 4.
Return to Master TOC Return to Section TOC A-7 INSTALLATION PREMISES WIRING CIRCUIT BREAKERS The WELDANPOWER 125 three-wire, grounded neutral generator allows it to be connected to premises wiring. However, the wiring procedure needed to meet the National Electric Code (NEC) regulations as well as city ordinances can be confusing. Matters get worse depending on whether you want the machine to be “hardwired” to the premises or only connected temporarily.
Return to Master TOC Return to Master TOC A-8 INSTALLATION CAUTION Certain Electrical devices cannot be powered by the WELDANPOWER 125. See Table A.2. TABLE A.2 ELECTRICAL DEVICE USE WITH THE WELDANPOWER 125. Type Common Electrical Devices 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.
Return to Master TOC Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION Operation...............................................................................................................................Section B Safety Instructions ......................................................................................................................B-2 General Description ....................................................................................................................
Return to Master TOC Return to Section TOC B-2 OPERATION WARNING OPERATING INSTRUCTIONS Read and understand this entire section before operating your WELDANPOWER 125. ARC RAYS can burn. SAFETY INSTRUCTIONS • Wear eye, ear, and body protection. WARNING Return to Master TOC Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC B-3 OPERATION RECOMMENDED APPLICATIONS WELDER The WELDANPOWER 125 provides excellent constant current DC welding output for stick (SMAW) welding and DC TIG welding using the “scratch” starting technique. THE K903 TIG Module can be added as an option to provide high frequency starting.
Return to Master TOC Return to Section TOC B-4 OPERATION CONTROLS AND SETTINGS All welder/generators controls are located on the Output Control Panel. Gasoline engine controls are mounted on the engine. See Figures B.1 and B.2 and the explanations that follow. FIGURE B.1 – OUTPUT PANEL CONTROLS 1 Return to Master TOC 9 Return to Section TOC B-4 10 8 7 2 Return to Master TOC Return to Section TOC 3 1. 2. 3. 4. 5.
Return to Master TOC Return to Section TOC B-5 OPERATION B-5 5. GROUND STUD: Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure. 8. 20 AMP, 115 VOLT DUPLEX RECEPTACLE: Connection point for supplying 115 volt power to operate one or two electrical devices. 6. 20 AMP CIRCUIT BREAKERS (2): Provide separate overload current protection for the 115 volt and 230 volt receptacles. 9.
Return to Master TOC Return to Section TOC B-6 OPERATION 7. CARBURETOR: Mixes air with fuel to obtain the smoothest operation under load or at idle. The WELDANPOWER 125 is shipped with the proper air/fuel mixture adjustment already set. DO NOT ADJUST THE AIR MIXTURE WITHOUT FOLLOWING THE PROCEDURES OUTLINED BY BRIGGS & STRATTON. BEFORE STARTING THE ENGINE 8. RECOIL STARTER: Manual, rope-type starter. The handle position allows easy starting from either ground level or pickup-truck level. 3.
Return to Master TOC Return to Section TOC B-7 OPERATION FIGURE B.3 FUEL SHUT-OFF AND CHOKE CONTROL 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. Choke Controls 3. Set the Idler Control switch to the “AUTOMATIC” position. See Figure B.4. Return to Master TOC 4. Pull the cord rapidly.
Return to Master TOC Return to Section TOC B-8 OPERATION BREAK-IN PERIOD WELDING OPERATION Any engine will use a small amount of oil during its “break-in” period. For the gasoline engine on the WELDANPOWER 125, break-in is about 50 running hours. GENERAL INFORMATION WARNING Check the oil frequently during break-in. Change the oil after the first 5 hours of operation. For more details, see the Maintenance section of this manual.
Return to Master TOC Return to Section TOC B-9 OPERATION TO USE THE WELDANPOWER 125 FOR WELDING: 1. Remove the flange nuts from the weld output terminals and place the work and electrode welding cables over the terminals. See Figure B.2. Replace and tighten the flange nuts securely. Be sure the connections are tight. 2. Select the appropriate electrode. See Table B.2, Electrode Selection Guide. This same table is also printed on the machine Output Control Panel. 3.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-10 B-10 OPERATION TABLE B.
Return to Master TOC Return to Section TOC B-11 OPERATION AUXILIARY POWER draws. (This information is given on the load device nameplate.) For example, a device rated 115 volts, 2 amps will need 230 watts of power (115 x 2 = 230). CAUTION Be sure that any electrical equipment plugged into the generator’s AC power receptacles can withstand a ±10% voltage and a ±3% frequency variation. Some electronic devices cannot be powered by the WELDANPOWER 125. Refer to Table A.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-12 B-12 OPERATION TABLE B.
Section C-1 TABLE OF CONTENTS -ACCESSORIESAccessories...........................................................................................................................Section C Options/Accessories...................................................................................................................C-2 Lincoln Electric Accessories ................................................................................................C-2 Briggs and Stratton Accessories ..........................
Return to Master TOC Return to Section TOC C-2 ACCESSORIES OPTIONS/ACCESSORIES BRIGGS AND STRATTON ACCESSORIES LINCOLN ELECTRIC ACCESSORIES The following options/accessories are available for your WELDANPOWER 125 from your local Briggs & Stratton Distributor. The following options/accessories are available for your WELDANPOWER 125 from your local Lincoln Distributor. Exhaust Deflector (REF 710281) – Directs exhaust either right, left, or downward, away from the operator.
D-1 TABLE OF CONTENTS -MAINTENANCEMaintenance .........................................................................................................................Section D Routine and Periodic Maintenance ............................................................................................D-2 Engine Maintenance.............................................................................................................D-2 Welder/Generator Maintenance .............................................
Return to Master TOC Return to Section TOC D-2 MAINTENANCE SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. D-2 OIL: Check the oil level after every 5 hours of operation or daily. BE SURE TO MAINTAIN THE OIL LEVEL.
Return to Master TOC Return to Section TOC D-3 D-3 MAINTANENCE AIR CLEANER: With normal operating conditions, the maintenance schedule for cleaning and re-oiling the foam pre-filter is every 25 hours and replacement of the air cleaner filter element every 100 hours. More frequent servicing is required with dusty operating conditions. Clean Rotating Screen: See Figure D.3. Clean the rotating screen on your machine’s engine as often as needed to remove dirt or debris that may collect on the screen.
Return to Master TOC Return to Section TOC D-4 D-4 MAINTENANCE CLEAN OR REPLACE SPARK PLUG: Clean or replace the spark plug after every 100 hours of operation or every season, whichever comes first. Do not blast the spark plug clean with an abrasive cleaning device. Clean the plug by scraping it or by using a wire brush. Wash the plug with a commercial solvent. After cleaning or when installing a new spark plug, set the terminal gap to .030 inch (.76 mm) with a feeler gauge. See Figure D.5.
Return to Master TOC Return to Section TOC D-5 MAINTENANCE TABLE D.2 – ENGINE MAINTENANCE PARTS Part Part Number OIL FILTER SPARK PLUG (STANDARD) SPARK PLUG (RESISTOR) NONE B&S 492167 B&S 491055 CHAMPION RC12YC B&S 710266 (CAN BE CLEANED AND REUSED) B&S 710268 (CAN BE CLEANED AND REUSED) AIR CLEANER CARTRIDGE Return to Master TOC Return to Section TOC AIR PRE-CLEANER (AS NEEDED) WELDER/GENERATOR MAINTENANCE STORAGE: Store the WELDANPOWER 125 in clean, dry, protected areas.
D-6 MAINTENANCE Return to Master TOC Return to Section TOC D-6 FIGURE D.6 – MAJOR COMPONENT LOCATIONS 5 6 Return to Master TOC Return to Section TOC 8 7 1 3 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4 2 1. 2. 3. 4. 5. 6. 7. 8.
Return to Master TOC Section E-1 Section E-1 TABLE OF CONTENTS -THEORY OF OPERATION SECTIONTheory of Operation .............................................................................................................Section E Power Supply Operation ..............................................................................................E-2 - E-3 Engine, Excitation, Rotor and Stator ..............................................................................
Return to Master TOC Return to Section TOC E-2 E-2 OPERATION FIGURE E.2 – ENGINE, EXCITATION, ROTOR AND STATOR CHOKE OUTPUT RECTIFIER BRIDGE POSITIVE OUTPUT TERMINAL NEGATIVE OUTPUT TERMINAL Return to Master TOC Return to Section TOC STATOR ENGINE MECHANICAL ROTATION CURRENT TRANSFORMER ROTOR SLIP RINGS ROTOR MAGNETO STATOR CAPACITORS IDLER SOLENOID + IDLER P.C.
Return to Master TOC Return to Section TOC E-3 E-3 OPERATION FIGURE E.3 – ROTOR FIELD FEEDBACK, AUXILIARY POWER AND ENGINE IDLE CONTROL CHOKE OUTPUT RECTIFIER BRIDGE POSITIVE OUTPUT TERMINAL NEGATIVE OUTPUT TERMINAL Return to Master TOC Return to Section TOC STATOR ENGINE MECHANICAL ROTATION CURRENT TRANSFORMER ROTOR SLIP RINGS ROTOR MAGNETO STATOR CAPACITORS IDLER SOLENOID + IDLER P.C.
Return to Master TOC Return to Section TOC E-4 E-4 OPERATION FIGURE E.4 – WELD WINDING, OUTPUT RECTIFIER AND CHOKE CHOKE OUTPUT RECTIFIER BRIDGE POSITIVE OUTPUT TERMINAL NEGATIVE OUTPUT TERMINAL Return to Master TOC Return to Section TOC STATOR ENGINE MECHANICAL ROTATION CURRENT TRANSFORMER ROTOR SLIP RINGS ROTOR MAGNETO STATOR CAPACITORS IDLER SOLENOID + IDLER P.C.
Return to Master TOC Section F-1 Section F-1 TABLE OF CONTENTS TROUBLE SHOOTING & REPAIR SECTION Troubleshooting & Repair Section .................................................................................Section F How to Use Troubleshooting Guide ......................................................................................F-2 PC Board Troubleshooting Procedures .................................................................................F-3 Troubleshooting Guide ......................
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-2 TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-3 TROUBLESHOOTING & REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. Turn the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-4 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) F-4 POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage is evident. 1. Contact your local Lincoln Authorized Field Service Facility. 1. Contact The Lincoln Electric Service Dept.
Return to Master TOC Return to Section TOC F-5 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS No weld output, the auxiliary power (230-115VAC) operates normally. Engine runs normally. Return to Section TOC F-5 1.
Return to Master TOC Return to Section TOC F-6 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Make sure that the control rheostat (R1) is set at maximum. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC 2. Check for a loose or faulty plug at the power receptacle.
Return to Master TOC Return to Section TOC F-7 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Low weld output and low auxiliary output. 1. The generator brushes may be worn. See the Maintenance section of this manual or contact your local Lincoln Electric Authorized Field Service Facility. Return to Master TOC 2.
Return to Master TOC Return to Section TOC F-8 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION Return to Master TOC Return to Section TOC POSSIBLE AREAS OF MISADJUSTMENT(S) ENGINE PROBLEMS Engine will not start. 1. Make sure the RUN/STOP Switch is in the “RUN” position. 1. Check the fuel line for breaks or obstructions. 2.
Return to Master TOC Return to Section TOC F-9 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION ENGINE PROBLEMS Engine will NOT idle down to low speed. 1. Make sure the idler control switch is in the “AUTO” idle position. Return to Master TOC 2. Remove any external load on the welder terminals or auxiliary power receptacles.
Return to Master TOC Return to Section TOC F-10 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION POSSIBLE AREAS OF MISADJUSTMENT(S) ENGINE PROBLEMS Engine idles down to low idle but will not stay at low idle. 1. Remove any external load on the welder terminals or auxiliary power receptacles.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-11 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-11 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION ENGINE PROBLEMS Engine will not go to high idle when attempting to weld.
Return to Master TOC Return to Section TOC F-12 TROUBLESHOOTING & REPAIR F-12 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION ENGINE PROBLEMS Return to Master TOC Return to Section TOC The welding arc is “cold.” The engine runs normally. The auxiliary power functions normally. 1.
Return to Master TOC Return to Section TOC F-13 TROUBLESHOOTING & REPAIR ROTOR VOLTAGE TEST WARNING Service and repair should be performed by only 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.
F-14 F-14 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR ROTOR VOLTAGE TEST (continued) FIGURE F.1 - LOCATION OF LEAD 202 FOR ROTOR VOLTAGE TEST GROUND STUD Return to Master TOC Return to Section TOC LEAD 202 CONNECTION (TOP TERMINAL, CASE FRONT IN PLACE Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TEST PROCEDURE 1. With the 5/16” nut driver, remove the 8 sheet metal screws that hold the top cover to the control box.
Return to Master TOC Return to Section TOC F-15 TROUBLESHOOTING & REPAIR ROTOR RESISTANCE TEST WARNING Service and repair should be performed by only 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-16 TROUBLESHOOTING & REPAIR F-16 ROTOR RESISTANCE TEST (continued) FIGURE F.2 – LOCATION OF ROTOR SLIP RINGS - BRUSH HOLDER ASSEMBLY REMOVED SLIP RINGS Return to Master TOC Return to Section TOC TEST PROCEDURE 1. Conduct the test with the gasoline engine OFF. 7. Measure the resistance across the rotor slip rings. 2. Remove the spark plug wire to prevent accidental engine kickback or starting. A.
Return to Master TOC Return to Section TOC F-17 TROUBLESHOOTING & REPAIR ROTOR RESISTANCE TEST (continued) FIGURE F.3 – BRUSHES RETAINED WITH CABLE TIE Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC CABLE TIE BRUSHES 9. Reinstall the brush holder assembly after the test. Depress the spring-loaded brushes into the holder and slip a suitable nonmetallic, fairly stiff retainer through the slots at the top and bottom of the holder.
Return to Master TOC Return to Section TOC F-18 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST WARNING Service and repair should be performed by only 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.
Return to Master TOC Return to Section TOC F-19 TROUBLESHOOTING & REPAIR F-19 OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.4 - OUTPUT RECTIFIER BRIDGE Strap 203 2 Return to Master TOC Return to Section TOC W 1 W 204 Return to Master TOC Return to Section TOC TEST PROCEDURE 1. Conduct this test with the gasoline engine OFF. 2. Remove the spark plug wire to prevent accidental engine kickback or starting. 3.
Return to Master TOC Return to Section TOC F-20 TROUBLESHOOTING & REPAIR MAIN STATOR TEST WARNING Service and repair should be performed by only 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.
Return to Master TOC Return to Section TOC F-21 TROUBLESHOOTING & REPAIR F-21 MAIN STATOR TEST (continued) FIGURE F.5 - LOCATION OF LEADS W1 AND W2 203 Strap 2 Return to Master TOC Return to Section TOC W 1 W 204 Return to Master TOC Return to Section TOC TEST PROCEDURE WARNING 1. With the 5/16" nut driver, remove the 8 sheet metal screws that hold the top cover to the control box. Remove the top cover. 2.
Return to Master TOC Return to Section TOC F-22 F-22 TROUBLESHOOTING & REPAIR MAIN STATOR TEST (continued) FIGURE F.6 - MAIN STATOR MOLEX PLUG TEST POINTS FIGURE F.6 MAIN STATOR MOLEX PLUG TEST POINTS FIGURE F.
Return to Master TOC Return to Section TOC F-23 TROUBLESHOOTING & REPAIR ROTOR “FLASHING” CIRCUIT TEST WARNING Service and repair should be performed by only 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.
Return to Master TOC Return to Section TOC F-24 F-24 TROUBLESHOOTING & REPAIR ROTOR “FLASHING” CIRCUIT TEST (continued) FIGURE F.8 - BRUSH HOLDER LEADS 201A(-) AND 202B (+) 201A(-) Return to Master TOC Slip Rings Return to Master TOC Return to Section TOC Return to Section TOC 202B(+) TEST PROCEDURE 1. With the 5/16" nut driver, remove the 8 sheet metal screws that hold the top cover to the control box. Remove the top cover. 3.
Return to Master TOC Return to Master TOC ROTOR “FLASHING” CIRCUIT TEST (continued) FIGURE F.10 - IDLER P.C. BOARD PIN ASSIGNMENTS WP125 IDLER Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR J2 TO CURRENT TRANSFORMER 16 (BLACK) 9B (BROWN) 14 (WHITE) 203 (RED) MOVING PARTS can injure. Return to Master TOC Keep away from moving parts. Return to Section TOC ENGINE EXHAUST can kill. Use in open, well ventilated areas or vent exhaust to the outside. 5.
Return to Master TOC Return to Section TOC F-26 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST WARNING Service and repair should be performed by only 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-27 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.11 - BLOWER PADDLE MARKED FOR STROBE-TACH METHOD Mark Return to Master TOC Return to Section TOC TEST PROCEDURE WARNING This test can be conducted by any of three methods. ENGINE EXHAUST can kill. Use in open, well ventilated areas or vent exhaust to the outside. Strobe-tach Method: 1.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-28 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.12 - IDLE SPEED ADJUSTMENT SCREW LOCATIONS HIGH IDLE INCREASE SPEED SCREW HIGH IDLE DECREASE SPEED SCREW GOVERNOR CONTROL LEVER CARBURETOR THROTTLE LEVER LOW IDLE SPEED SCREW 5. ADJUST HIGH IDLE: With the Idler Switch set on HIGH, the tach should read between 3700 and 3800 RPM. a.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-29 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.13 - LOW IDLE ADJUSTMENT NUT ON IDLER SOLENOID Solenoid Housing 3/8" Low Idle Adjustment Nut Rod 7. After you set the low idle speed, set the Idler Switch to HIGH and recheck the high idle speed. Adjust if necessary. Frequency Counter Method: Return to Master TOC Return to Master TOC Return to Section TOC 1.
Return to Master TOC Return to Section TOC F-30 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) 4. ADJUST LOW IDLE: Using a piece of dowel rod or a long screw driver, push the governor arm back until the Carburetor Throttle Lever rests against the Low Idle Speed screw. See Figure F.12. You can also push the arm back with your hand, but this is not recommended because you could be burned by the hot muffler. Adjust the Low Idle Speed screw until the frequency counter reading is 34.
Return to Master TOC Return to Section TOC F-31 F-31 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM Return to Master TOC Return to Section TOC CH1 0 volts Return to Master TOC Return to Section TOC 50 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.
Return to Master TOC Return to Section TOC F-32 F-32 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY) HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 1 Period = 16.2 ms @ 3700 rpm Return to Master TOC Return to Section TOC CH1 0 volts Return to Master TOC Return to Section TOC 50 volts This is the typical AC output voltage generated from a properly operating machine.
Return to Master TOC TYPICAL WELD OUTPUT WAVEFORM MACHINE LOADED CH1 0 volts 20 volts 5 ms Return to Master TOC Return to Section TOC MACHINE LOADED TO 125 AMPS AT 25 VAC This is the typical DC output voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time. The mahine was loaded with a resistance grid bank. Note: Scope probes connected at machine output terminals.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-34 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM CH1 0 volts Return to Master TOC Return to Section TOC 50 volts SCOPE SETTINGS Return to Master TOC 5 ms This is not the typical DC output voltage waveform. Note the “gap” in the waveform. One output diode was disconnected to simulate an “open” diode.
Return to Master TOC Return to Section TOC F-35 TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only 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.
Return to Master TOC Return to Section TOC F-36 TROUBLESHOOTING & REPAIR F-36 BRUSH REMOVAL AND REPLACEMENT (continued) FIGURE F.14 - BRUSHES RETAINED WITH CABLE TIE CABLE TIE Return to Master TOC Return to Section TOC BRUSHES PROCEDURE Return to Master TOC Return to Section TOC 1. Remove the spark plug wire. 2. Open the brush holder assembly cover. Squeeze the 2 tabs and depress the cover at the top with a screw driver or your fingernail. The cover will drop open on its bottom hinge. 3.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-37 TROUBLESHOOTING & REPAIR F-37 BRUSH REMOVAL AND REPLACEMENT (continued) PROCEDURE (continued) 8. To reinstall the brush holder assembly, depress the spring-loaded brushes into the holder and slip a suitable non-metallic, fairly stiff retainer through the slots at the top and bottom of the holder.
Return to Master TOC Return to Section TOC F-38 TROUBLESHOOTING & REPAIR RHEOSTAT REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-39 TROUBLESHOOTING & REPAIR RHEOSTAT REMOVAL AND REPLACEMENT (continued) FIGURE F.15 - RHEOSTAT REMOVAL See Figure F.15 for steps 3 - 9. PROCEDURE 1. Remove the spark plug wire. 3. With the 5/16” nut driver and the 5/16” wrench, remove the 6 screws that hold the control panel in place. Move the panel aside as far as the leads will allow. 8. To reinstall the rheostat, replace each of the brass screws.
Return to Master TOC Return to Section TOC F-40 TROUBLESHOOTING & REPAIR FIELD CAPACITOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only 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.
Return to Master TOC Return to Section TOC F-41 TROUBLESHOOTING & REPAIR F-41 FIELD CAPACITOR REMOVAL AND REPLACEMENT (continued) FIGURE F.16 - DISCHARGING THE FIELD CAPACITOR Attachment for 201C 201B 201A (+) Attachment for 202 202B (-) Cable Tie Return to Master TOC Return to Section TOC Jumper Capacitor PROCEDURE 1. Remove the engine spark plug wire. Return to Master TOC Return to Section TOC 2.
Return to Master TOC Return to Section TOC F-42 TROUBLESHOOTING & REPAIR FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only 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.
Return to Master TOC Return to Section TOC F-43 TROUBLESHOOTING & REPAIR FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.17 - DISCHARGING THE FIELD CAPACITOR Attachment for 202 202B (-) Attachment for 201C 201B 201A (+) Return to Master TOC Return to Section TOC Jumper Cable Tie Capacitor PROCEDURE 1. Remove the engine spark plug wire. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 2.
Return to Master TOC Return to Section TOC F-44 F-44 TROUBLESHOOTING & REPAIR FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.18 - FIELD DIODE BRIDGE LOCATION 200 (Red) 200C (Red) 7A (Blue) + 9A (Brown) 9B (Brown) 201 (Black) 201C (Black) Field Feild Diode DiodeBridge Bridge Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC – 5. The field diode bridge is mounted to the sheet metal just above the capacitor. See Figure F.18.
Return to Master TOC Return to Section TOC F-45 TROUBLESHOOTING & REPAIR IDLER PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT WARNING If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
Return to Master TOC IDLER PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.19 - IDLER P.C. CIRCUIT BOARD WP125 IDLER MOUNTING SCREWS Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR J2 J1 MOUNTING SCREW PROCEDURE CAUTION Before starting the following procedure, refer to the topic "PC Board Troubleshooting Procedures" at the beginning of this section. Return to Master TOC Return to Section TOC 1.
Return to Master TOC Return to Section TOC F-47 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT WARNING If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
Return to Master TOC Return to Section TOC F-48 TROUBLESHOOTING & REPAIR F-48 OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.20 - OUTPUT RECTIFIER CONNECTIONS 203 2 Return to Master TOC Return to Section TOC W 1 W 204 PROCEDURE 2. With the 5/16" nut driver, remove the 8 sheet metal screws from the case top. Return to Master TOC Return to Section TOC 1. Remove the engine spark plug wire to prevent accidental kickback or starting. 3.
Return to Master TOC Return to Section TOC F-49 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) 11. With the 7/16" wrench, install the choke lead and the #203 lead to the positive heat sink. 12. With the 7/16" wrench, install the "N" negative lead and the #204 lead to the negative heat sink. 13. With the 7/16" wrench, install the heavy leads W1 and W2 to the stud terminals.
Return to Master TOC Return to Section TOC F-50 TROUBLESHOOTING & REPAIR OUTPUT CHOKE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-51 TROUBLESHOOTING & REPAIR OUTPUT CHOKE REMOVAL AND REPLACEMENT (continued) FIGURE F.21 - OUTPUT CHOKE MOUNTING DETAILS PROCEDURE Return to Master TOC Return to Section TOC 1. Remove the engine spark plug wire to prevent accidental kickback or starting. 2. With the 5/16" nut driver, remove the 8 sheet metal screws from the case top. Return to Master TOC 7.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-52 TROUBLESHOOTING & REPAIR OUTPUT CHOKE REMOVAL AND REPLACEMENT (continued) 14. Reassembly: Install the output choke assembly by setting it down into position. Fit the idler solenoid plunger into the solenoid housing. 21. Replace the output rectifier bridge. Refer to "THE OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT" procedure in this section of the manual. 15.
Return to Master TOC Return to Section TOC F-53 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only 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.
Return to Master TOC Return to Section TOC F-54 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT(continued) STATOR REMOVAL PROCEDURE 1. Remove the engine spark plug wire to prevent accidental kickback or starting. 2. Perform the Output Rectifier Bridge Removal procedure. 3. Perform the Output Choke Removal procedure. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 4. Remove lead #14A from the control box assembly.
Return to Master TOC Return to Section TOC F-55 TROUBLESHOOTING & REPAIR F-55 STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.22 - STATOR END BRACKET SUPPORT AND THRU-BOLTS THRUBOLTS Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC THRUBOLTS SUPPORT NUTS 13. Slide a short length of 2 X 4 under the engine to support it when the stator is removed. 16. Lift up the stator and slide out the support bracket.
Return to Master TOC Return to Section TOC F-56 TROUBLESHOOTING & REPAIR F-56 STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.23 - ROTOR WITH STATOR REMOVED Return to Master TOC Return to Section TOC ROTOR THRU-BOLT Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC ROTOR REMOVAL PROCEDURE 1. To remove the rotor, double check that the spark plug wire is disconnected.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-57 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.24 - CHECKING ROTOR-STATOR AIR GAP FEELER GAUGE 5. Install the end bracket support. Return to Master TOC Return to Master TOC 6. Install the bottom two end bracket thrubolts. Return to Section TOC STATOR ROTOR 4. Install the end bracket.
Return to Master TOC Return to Section TOC F-58 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) 18. Install the output choke. Refer to the topic "OUTPUT CHOKE REMOVAL AND REPLACEMENT" in this section of the manual. 19. Install the output rectifier bridge. Refer to the topic "OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT" in this section of the manual.
Return to Master TOC Return to Section TOC F-59 F-59 TROUBLESHOOTING & REPAIR 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. OR • If you repair or replace any electrical components.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC NOTES WELDANPOWER 125
Return to Master TOC Section G-1 Section G-1 TABLE OF CONTENTS DIAGRAMS SECTION Diagrams Section............................................................................................................Section G Wiring Diagram Weldanpower 125 (Codes 10158 & 10160) ................................................G-2 M17578 Idler PC Board Schematic ......................................................................................G-3 Dimension Print Weldanpower 125.....................................
3 1 RED 10 5 201B 209 9B WHITE 201A BLK (-) (+) RED 202B 200A ROTOR 16 16 HI 6 1 RED 204 FD BRN 202 D1 (+) (-) RED 200 WHITE BOARD IDLER P.C. 208 3.
+8V 10K 133K R6 D13 14 R20 X1 47.5K 1A Q2 8 9 300V 47.5K 13 3.01K Q3 Return to Section TOC Return to Master TOC 2N4401 R7 R10 R8 G .5 C14 68 63V 5W 1W 15V DZ2 Q1 18A 200V COM 5.11K R9 5.11K DZ1 8.2V 1W COM R30 4.75K R12 26.7K D6 1N4936 C5 18 15V R18 162 D S C6 68 63V C9 D2 D11 1N5406 D5 +8V 10K DZ4 15V 1W D1 CR1 12Vdc .25 1N5406 1 2 Q4 1A 100V COM DZ3 10V 5W 5 4 +t 10K 1 X1 2 C11 .
Return to Master TOC 30.00 762 REF. 13.62 REF. 346 A M17614 Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC REF. 21.13 REF. 537 REF. Return to Section TOC 20.00 508 R ELECTRIC LINCOLN 7.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC G-5 NOTES WELDANPOWER 125 G-5
M17578-1 R16 R17 C8 R26 R27 D9 D4 R13 C11 TP1 CR1 D3 D1 D2 R15 DZ3 D11 R14 C14 R18 X1 C1 D12 R5 DZ2 R30 Q1 Q2 R2 R3 R23 R4 C7 R29 C3 R22 R25 DZ4 R28 C12 R24 C13 Q4 C2 R11 Return to Master TOC D6 R1 R12 R10 R20 R6 R7 C9 DZ1 Return to Master TOC C5 D5 R9 Return to Section TOC C6 D10 D13 R8 Return to Section TOC Q3 Return to Master TOC J2 J1 Return to Master TOC M17578 IDLER PC BOARD IDLER Return to Section TOC G-6 DIAGRAMS WP125 Return
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-7 DIAGRAMS G-7 M17578 IDLER PC BOARD BILL OF MATERIALS Item C1 C2 C3,C13 C5,C12 C6,C14 C7,C9 C8 C11 CR1 D1,D2,D3,D4,D9 D5,D10,D11,D13 D6,D12 DZ1 DZ2,DZ4 DZ3 J1 J2 Q1 Q2 Q3 Q4 R1 R2 R3,R5,R23, R24,R28 R4 R6 R7,R20 R8,R9 R10 R11 R12 R13 R14 R15 R16,R17,R26,R27 R18 R22 R25 R29 R30 TP1 X1 Description CAPACITOR-TAEL,39,10V,10% CAPACIT
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC G-8 NOTES WELDANPOWER 125 G-8