RETURN TO MAIN MENU WELDMARK 225 IM806 September, 2005 For Machines with Code Number 10992 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.
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.
ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 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. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii 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.
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 Thank You for selecting a QUALITY product We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.
TABLE OF CONTENTS Page Installation........................................................................................................................................Section A Technical Specifications.................................................................................................................A-1,A-2 Installation Instructions. ........................................................................................................................A-3 Safety Precautions.................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - WELDMARK 225 (WEM 2239-2 CSA MEETS CANADIAN STD) INPUT - GASOLINE ENGINE Make/Model Description Horsepower 2 cylinder 4 Cycle Kohler CH20S Air-Cooled Gasoline Engine. Aluminum Alloy with Cast Iron Liners, Electrical Ignition Speed (RPM) Displacement cu. in. (cu. cm.) High Idle 3700 20 HP @ 3600 RPM (Kohler) 38(624)-Kohler Full Load 3500 Capacities Fuel: 9 Gal (34 L) Lubricating Oil: 2.0 Qts (1.
A-2 A-2 INSTALLATION AC STICK / TIG (CC) OUTPUT SPECIFICATIONS OUTPUT VOLTS AC (RMS) 80 A 225 OUTPUT RANGE B 50 OUTPUT RANGE 70 60 50 40 30 20 B A 10 0 0 50 100 150 200 250 OUTPUT AMPS DC STICK / TIG (CC) OUTPUT OUTPUT VOLTS DC (RMS) 80 A 210 OUTPUT RANGE B 50 OUTPUT RANGE 70 60 50 40 30 20 A B 10 0 0 50 100 150 200 250 300 350 OUTPUT AMPS DC WIRE FEED (CV) OUTPUT 40 OUTPUT VOLTS DC (RMS) 35 30 25 20 15 10 CV OUTPUT RANGE 5 0 0 50 100 150 200 250 OUTPUT AMPS WELDMARK 22
A-3 A-3 INSTALLATION INSTALLATION INSTRUCTIONS Safety Precautions WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. -----------------------------------------------------------------------ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing.
A-4 A-4 INSTALLATION TOWING The recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle(1) is Lincoln’s K957-1. If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be considered are as follows: 1. Design capacity of trailer vs. weight of Lincoln equipment and likely additional attachments. 2.
A-5 A-5 INSTALLATION ANGLE OF OPERATION LOCATION / VENTILATION Internal combustion engines are designed to run in a level condition which is where the optimum performance is achieved. The maximum angle of operation for the engine is 15 degrees from horizontal in any direction. If the engine is to be operated at an angle, provisions must be made for checking and maintaining the oil at the normal (FULL) oil capacity in the crankcase in a level condition.
A-6 CONNECTION OF THE LN-7 TO THE WELDMARK 225 Shut the welder off. • Connect the LN-7 and the K240 contactor kit per instructions on the connection diagram S17742 (can be found in the back of this manual). • • WELDER OPERATION WELDER OUTPUT • • A-6 INSTALLATION Place the “RANGE” switch to the “WIRE FEED” position and the “POLARITY” switch to the desired polarity. Place the “IDLER” switch in the “HIGH” idle position. The engine idling device may not function when welding in the “WIRE FEED” mode.
A-7 INSTALLATION GND MOTOR STARTING 115 V 230 V Most 1.5 hp AC single phase motors can be started if there is no load on the motor or other load connected to the machine, since the full load current rating of a 1.5 hp motor is approximately 20 amperes (10 amperes for 230 volt motors). The motor may be run at full load when plugged into only one side of the duplex receptacle. Larger motors through 2 hp can be run provided the receptacle rating as previously stated is not exceeded.
A-8 A-8 INSTALLATION TABLE lll ELECTRICAL DEVICE USE WITH THE WELDMARK 225 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. Voltage spikes or high voltage regulation can cause the capacitative elements to fail.
A-9 INSTALLATION A-9 AUXILIARY POWER WHILE WELDING It must be noted that the above auxiliary power ratings are with no welding load. Simultaneous welding and power loads are permitted by following Table III. The permissible currents shown assume that current is being drawn from either the 115V or 230V supply (not both at the same time). Also, the “Output Control” is set at “10” for maximum auxiliary power.
A-10 A-10 INSTALLATION Figure 1 CONNECTION OF WELDMARK 225 TO PREMISES WIRING 230 VOLT GROUNDED CONDUCTOR POWER 230 Volt 60 Hz. 3-Wire Service 115 VOLT COMPANY 115 VOLT METER NEUTRAL BUS N LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.
B-1 OPERATION GENERAL DESCRIPTION • K930-1 TIG Module Available. The Weldmark 225 is a twin-cylinder, gasoline driven, multiprocess arc welder and AC power generator. It is built in a heavy gauge steel case for durability on the job site. • Remote Control Receptacle Kit Available. DESIGN FEATURES B-1 • Electronic Engine Idler. Engine Automatically Goes to Low Idle in 10 to 14 Seconds after Welding or Use of Auxiliary Power. Includes High Idle Switch. • Electric Starting.
B-2 B-2 OPERATION WELDMARK 225 Approximate Fuel Consumption KOHLER CH20S 20 H.P. COMMAND Low Idle - No Load 2200 RPM High Idle - No Load 3700 RPM AC CC Weld Output 225 Amps @ 25 Volts DC CC Weld Output 210 Amps @ 25 Volts DC CV Weld Output 200 Amps @ 20 Volts Auxiliary Power 8000 Watts .4 Gallons/Hour (1.5 Liters/Hour) .9 Gallons/Hour (3.5 Liters/Hour) 1.3 Gallons/Hour (5.0 Liters/Hour) 1.4 Gallons/Hour (5.3 Liters/Hour) 1.2 Gallons/Hour (4.5 Liters/Hour) 1.4 Gallons/Hour (5.
B-3 OPERATION Starting/Shutdown Instructions B-3 STOPPING THE ENGINE Starting the Engine Remove all welding and auxiliary power loads and allow engine to run at low idle speed for a few minutes to cool the engine. WARNING • Do not touch electrically live parts of electrode with skin or wet clothing. • Keep flammable material away. • Insulate yourself from work and ground. Wear eye, ear, and body protection. • Keep your head out of the fumes.
B-4 WELDING PROCESS DUTY CYCLE Duty Cycle is the the percentage of time the load is being applied in a 10 minute period. For example, a 60% duty cycle reresents 6 minutes of load and 4 minutes of no load in a 10 minute period. STICK (CONSTANT CURRENT) WELDING Connect welding cables to the "TO WORK” and "ELECTRODE” studs. Start the engine. Set the "Polarity” switch to the desired polarity. Set the “RANGE” switch to a setting that is equal to or slightly greater than the desired welding current.
B-5 B-5 OPERATION SUMMARY OF WELDING PROCESSES CONTROL CABLE USED IDLE MODE ELECTRODE WHEN NOT WELDING STICK No AUTO Hot Touch electrode to work. Welding starts immediately and engine goes to high idle. TIG/K7930-1/K938-1, K936-( ) /K892-1 (WITH AMPTROL) Yes HIGH Cold Press Amptrol, contactor closes, welding starts immediately. WIRE FEED, LN-25 WITH INTERNAL CONTACTOR No AUTO Cold Press gun trigger, LN-25 contactor closes. Welding starts immediately and engine goes to high idle.
C-1 OPTIONAL EQUIPMENT ACCESSORIES (Field Installed) K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS - For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.). Order: K957-1 Trailer K958-1 Ball Hitch K958-2 Lunette Eye Hitch K959-2 Fender & Light Kit K965-1 Cable Storage Rack K889-2 & -3 Two-Wheel Undercarriage - For moving by hand. Overall Width 29 in (.
C-2 ACCESSORIES RECOMMENDED EQUIPMENT STICK K704 Accessory Kit which includes: • Electrode Holder & Cable • Work Clamp & Cable • Headshield K892-1 Remote Control Receptacle Kit and K857 Remote Control Kit are optional for remote current control.
D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS CAUTION WARNING Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts. Do not put your hands near the engine cooling blower fan.
D-2 MAINTENANCE Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SG or SH. Always check the API SERVICE label on the oil container to be sure it includes the letters SG or SH. SAE 10W-30 is recommended for general, all-temperature use, -5 F to 104 F (-20 C to 40 C). See Engine Owner’s Manual for more specific information on oil viscosity recommendations.
D-3 D-3 MAINTENANCE ENGINE ADJUSTMENTS WARNING GASES FROM BATTERY can explode. • Keep sparks, flame and cigarettes away from battery. OVERSPEED IS HAZARDOUS To prevent EXPLOSION when: • INSTALLING A NEW BATTERY - disconnect negative cable from old battery first and connect to new battery last. WARNING The maximum allowable high idle speed for this machine is 3750 RPM, no load. Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed.
D-4 MAINTENANCE GFCI RECEPTACLE TESTING AND RESETTING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage. • If the equipment has been shut down, it must be restarted.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by 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.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) No welder or output power. Engine will not idle down to low speed. Engine will not go to high idle when attempting to weld. POSSIBLE CAUSE 1. Open in miscellaneous leads. 2. Open lead in flashing or field circuit. 3. Faulty rotor. 4. Faulty Potentiometer (R1). 5. Faulty stator Field winding. 6. Faulty Field rectifier (D2). 7. Faulty P.C. Board. 1. Idler switch on High Idle. 2.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Engine will not go to high idle when using auxiliary power. Engine will not crank or is hard to crank. Engine shuts down. POSSIBLE CAUSE 1. No voltage signal from the current sensor. 2. Auxiliary power load less than 100 to 150 watts. 3. Faulty P.C. Board. 1. Battery will not hold a charge. Faulty Battery. 2. No or insufficient charging current. 3. Loose battery cable connection(s). 1.
WELDMARK 225 AC B+ N.A.
F-2 F-2 DIAGRAMS WELDMARK 225 / LN-25 ACROSS THE ARC CONNECTION DIAGRAM WARNING Do not operate with panels open. Keep guards in place. Disconnect NEGATIVE (-) BATTERY LEAD Keep away from moving parts. before servicing. Only qualified personnel should install,use Do not touch electrically live parts. or service this equipment. 6 PIN AMPHENOL OPTIONAL K444-1 REMOTE CONTROL LN-25 WIRE FEEDER TO WORK ELECTRODE WORK CLIP LEAD TO WORK TO WORK ELECTRODE CABLE N.A.
FOR OIL FILTER REMOVAL 2.75 WELDMARK 225 9.09 17.00 9.31 9.09 9.29 OF SHAFT 19.11 C L 26.59 30.28 11.31 8.80 21.95 42.25 30.00 42.00 UNDERCARRIAGE MOUNTING HOLES 21.21 CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK.
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
•Manufactured by Lincoln Electric Company • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.