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Lincoln Electric Weldanpower 125, Service Manual

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Lincoln Electric Weldanpower 125 Service Manual Download Page 97

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TROUBLESHOOTING & REPAIR

F-59

F-59

WELDANPOWER 125

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.    

ENGINE OUTPUT

No Load RPM

Load RPM

Maximum Speed

3800

3500

Minimum Speed

3700

3300

WELDER/GENERATOR OUTPUT

1

Output Control

Field Volts

Field Amps

Open Circuit

Load Volts

Load Amps

Volts

RMS

Maximum

40 - 47

4.0 - 6.4

75 - 82

22 - 28

125 - 135

Minimum

–

–

70 - 78

23 - 27

40 - 55

AUXILIARY POWER RECEPTACLE OUTPUT

1

230 Volt Receptacle

115 Volt Receptacle

2

Output

Open Circuit

Load Volts

Load Amps

Open Circuit

Load Volts

Load Amps

Control

Volts

Volts

Maximum

240 - 260

208 - 234

20.2 - 22.0

120 - 130

104 - 117

20.2 - 22.0

1 

Current Control Dial set at MAXIMUM.

2 

Output values of each receptacle can vary within the range shown but must be within 2 volts of each other.

Summary of Contents for Weldanpower 125

Page 1: ...THROUGHOUT And most importantly think before you act and be careful SERVICE MANUAL World s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors Sales and Service through s...

Page 2: ...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 Z...

Page 3: ...de holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch elect...

Page 4: ...re 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 ava...

Page 5: ...laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montante...

Page 6: ...lications B 3 Operational Features and Controls B 3 Design Features and Advantages B 3 Welding Capability B 3 Limitations B 3 Controls and Settings B 4 Engine Operation B 6 Accessories Section C Maint...

Page 7: ...4 Lifting A 4 Pre operation Engine Service A 4 Oil A 4 Fuel A 4 Spark Arrester A 4 Electrical Output Connections A 5 Welding Cable Connections A 5 Cable Size and Length A 5 Cable Installation A 6 Mach...

Page 8: ...in Manual Fuel 1 6 gal 6 0 l Stratton 4 cycle Full Load 296 cc Recoil Vanguard air cooled 3750 RPM start Manual Oil 1 25 qt 1 2 l gasoline High Idle choke 9 HP 2400 RPM 3600 RPM Low Idle RATED OUTPUT...

Page 9: ...safety hazards and cause improper operation and corrosion of parts Always operate the WELDANPOWER 125 with the case roof on and all machine components completely assembled This will protect you from t...

Page 10: ...me away from the fuel tank OIL 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...

Page 11: ...ngths to reduce voltage drops TABLE A 1 RECOMMENDED WELDING CABLE SIZE AND LENGTH TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Size for 125 amp Cable Length 30 Duty Cycle 0 50 feet 0 15 me...

Page 12: ...panel see Figure A 1 to a suitable earth ground such as a metal pipe driven into the ground Do not ground the machine to a pipe that carries explosive or combustible material When the WELDANPOWER 125...

Page 13: ...and the utility meter The WELDANPOWER 125 does not have a combined 115 230 volt twist lock receptacle and cannot be con nected to a premises as described in other Lincoln lit erature Remember that th...

Page 14: ...com mended for 100 fail safe operation DO NOT RUN THESE DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS Inductive Single phase induction motors These devices require large drills well pumps grinders s...

Page 15: ...trols B 3 Design Features and Advantages B 3 Welding Capability B 3 Limitations B 3 Controls and Settings B 4 Welder Generator Controls B 4 Gasoline Engine Controls B 5 Engine Operation B 6 Before Sta...

Page 16: ...reas or vent exhaust to the outside Do not stack anything on or near the engine MOVING PARTS can injure Do not operate this equipment with any of its doors open or guards off Stop the engine before se...

Page 17: ...gle 20 amp 230 volt generator receptacle Duplex 20 amp 115 volt generator receptacle Integrated generator output overload protection through two 20 amp circuit breakers Welded tube full roll cage fram...

Page 18: ...holder or the work cable For DC welding the electrode holder should be connected to the Weld Positive Output Terminal and the work cable to the Weld Negative Output Terminal For DC welding the electro...

Page 19: ...s low 5 AIR CLEANER Filters intake air to the carburetor See ENGINE MAINTENANCE in the Maintenance section of this manual for details about the specif ic type of air cleaner to use 6 IDLER CONTROL SWI...

Page 20: ...around the oil fill then remove the dipstick 3 Fill if necessary to full mark on the dipstick Do NOT screw in the dipstick to check 4 Replace the dipstick and tighten securely For more details on che...

Page 21: ...ith the choke in the left position more than one time Repeated pulls on a choked engine will flood the carburetor If you don t feel resistance when you pull the recoil cord gently hit the starter hous...

Page 22: ...MATION Do not touch electrically live parts or elec trodes with your skin or wet clothing Do not breathe welding fumes or gases Use ventilation or exhaust to remove weld ing fumes from the breathing a...

Page 23: ...section of the manual 2 Allow the electrode and work to cool completely 3 Remove the work clamp from the work 4 Remove any remaining piece of electrode from the electrode holder 5 If you are finished...

Page 24: ...THINNER OPERATION B 10 B 10 WELDANPOWER 125 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 Retur...

Page 25: ...ws 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 You can use Table B 3 GENERATOR POWER APPLI CATIONS to de...

Page 26: ...00 4 000 Sump Pump 600 1 500 2 400 Toaster 1 100 Weed Trimmer 500 Lincoln 100 or 125 Amp Wire Feeder Welder 4 000 NOTES Wattages listed are approximate Check your equipment for actual wattage Equipmen...

Page 27: ...ssories Section C Options Accessories C 2 Lincoln Electric Accessories C 2 Briggs and Stratton Accessories C 2 Section C 1 Section C 1 WELDANPOWER 125 Return to Master TOC Return to Master TOC Return...

Page 28: ...s one UL approved 115 volt ground fault circuit interruptor duplex type receptacle with cover and installation instructions Replaces the factory installed 115 volt receptacle Each side of the GFCI dup...

Page 29: ...Section D Routine and Periodic Maintenance D 2 Engine Maintenance D 2 Welder Generator Maintenance D 5 Major Component Locations D 6 D 1 D 1 WELDANPOWER 125 Return to Master TOC Return to Master TOC...

Page 30: ...ay be required depending on your specific application and operating conditions Table D 2 shows engine maintenance replacement parts and numbers OIL Check the oil level after every 5 hours of operation...

Page 31: ...the water is clear 4 Allow to stand and air dry before reinstalling Carefully place the pre cleaner back over the cartridge and reinstall the air cleaner cover and wingnuts CLEAN ENGINE Remove dirt a...

Page 32: ...reassemble the cylinder head and block Turn down the screws finger tight Torque the screws in a staggered sequence to 165 inch pounds 19 N m MAINTENANCE D 4 D 4 WELDANPOWER 125 Return to Section TOC R...

Page 33: ...al for the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator overhaul is necessary Remove the brushes and clean the slip rings with fine grit sand paper Do not at...

Page 34: ...er TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE D 6 MAJOR COMPONENT LOCATIONS 1 CRADLE ASSEMBLY 2 ROTOR BLOWER AND BEARING ASSEMBLY 3 STATOR ASSEMBLY 4 BRUSH AND BRUSH HOL...

Page 35: ...3 Weld Winding Output Rectifier and Choke E 4 ENGINE MECHANICAL ROTATION STATOR ROTOR STATOR CHOKE ROTOR SLIP RINGS CAPACITORS IDLER SOLENOID IDLER P C BOARD IDLE SWITCH RHEOSTAT HOUR METER 115 AND 2...

Page 36: ...ionary windings of the main alterna tor stator Three separate and isolated windings are incorporated in the stator lamination assembly Each winding set has a different number of turns producing differ...

Page 37: ...ng at high speed 3700 RPM a 230VAC voltage is developed in the stator auxiliary winding This winding is tapped Each half of this winding pro vides 115 VAC to each side of the 115V duplex recep tacle T...

Page 38: ...e current transformer to the out put rectifier bridge where the AC voltage is rectified to a DC voltage The DC current path from the output of the rectifier bridge is through the choke where the DC is...

Page 39: ...Waveform 115 VAC Supply F 32 Typical Weld Output Waveform Machine Loaded F 33 Abnormal Open Circuit Weld Voltage Waveform F 34 Replacement Procedures Brush Removal and Replacement F 35 Rheostat Remova...

Page 40: ...ISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without remov...

Page 41: ...hich could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag If the PC Board uses protective shorting jumpers don t remove them until installa...

Page 42: ...TOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical dam age is evident 1 Contact your local Lincoln Authorized Field Service Facility 1 Con...

Page 43: ...ry power 230 115VAC operates nor mally Engine runs normally 1 Check the open circuit voltage OCV at the welder output ter minals Normal is 75 to 82VDC with engine at high idle 3750 RPM and the output...

Page 44: ...you proceed Call 216 383 2531 or 1 800 833 9353 PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS No auxiliary power welding out put is normal engine run...

Page 45: ...ROBLEMS SYMPTOMS 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...

Page 46: ...l 4 Adjust the choke to prevent car buretor flooding 5 Check the spark plug wire for loose or faulty connections 1 Check the fuel line for breaks or obstructions 2 The spark plug may be faulty Replace...

Page 47: ...EAS 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 2 Remove any external load...

Page 48: ...rvice Facility 1 The engine low idle RPM may be set too low Perform the Engine Throttle Adjustment Test 2 With the idler control switch in the AUTO position and all external loads removed check for 12...

Page 49: ...ding output is normal when the idler control switch is in the HIGH position Automatic idle function works properly when the auxiliary power is loaded 1 Make sure the welding cables and connections are...

Page 50: ...MISADJUSTMENT S RECOMMENDED COURSE OF ACTION ENGINE PROBLEMS The welding arc is cold The engine runs normally The auxiliary power functions normally 1 Check for loose or faulty con nections at the wel...

Page 51: ...our safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to p...

Page 52: ...t high idle Set the output control rheostat at the MAXIMUM setting 3 Set the volt ohmmeter at the DC position 4 Place the positive probe on lead 202 two red wires joined together where it con nects at...

Page 53: ...ur safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to pe...

Page 54: ...h a screw driver or your fin gernail The cover will drop open on its bottom hinge 5 With the 1 4 nut driver remove the 2 screws that hold the brush holder assem bly in place 6 Slide the brush holder a...

Page 55: ...aded brush es into the holder and slip a suitable non metallic fairly stiff retainer through the slots at the top and bottom of the holder A cable tie works well see Figure F 3 This will hold the brus...

Page 56: ...s manual 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 trou bleshooting as...

Page 57: ...bly See Figure F 4 6 Electrically isolate the diode pigtails 7 With the volt ohmmeter or diode tester check the resistance of each of the four diodes from their pigtail leads to their respective heat...

Page 58: ...f 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 trou bleshooting assistance b...

Page 59: ...e in run ning during the test 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 3 Start the engine and run it...

Page 60: ...he molex plug however it s best to check them at the rectifier bridge 9 Check for 21 5 VAC at leads 9A Brown to 15A Yellow See Figure F 6 10 If any ONE of the voltage readings are incorrect the main s...

Page 61: ...manual 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 trou bleshooting assi...

Page 62: ...Connect the negative lead of the DC ammeter to lead 201A and the positive lead to the brush holder 4 Remove lead 7A from field diode bridge rectifier D1 See Figure F 9 Electrically isolate the lead TR...

Page 63: ...sure that all 201 leads have continuity zero ohms to case ground 9 If normal flashing voltage is NOT present from lead 202 to case ground check the continuity of lead 202 to the idler P C board Also...

Page 64: ...he test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION If the ma...

Page 65: ...See Figure F 11 3 Connect the strobe tach according the manufacturer s instructions MOVING PARTS can injure Keep away from moving parts ENGINE EXHAUST can kill Use in open well ventilated areas or ven...

Page 66: ...y to move the Governor Control Lever There should be no move ment The two high idle speed screws are designed to work against opposite sides of the Governor Control Lever tab so that no movement and t...

Page 67: ...urn the High Idle Increase Speed screw clockwise until the screw contacts the tab on the Governor Control Lever Do NOT tighten the screw any further as this may cause the tab to bend See Figure F 12 b...

Page 68: ...econds turn the High Idle Increase Speed screw counter clock wise several turns Turn the High Idle Decrease Speed screw clockwise until the waveform period is 16 2 millisec onds See Figure F 12 Next t...

Page 69: ...0 volts SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal This is the typical output voltage gen erated from a properly operating machine Note that each vertical...

Page 70: ...ontal Sweep 5 ms Div Coupling DC Trigger Internal CH1 0 volts 5 ms 50 volts This is the typical AC output voltage generated from a properly operating machine Note that each vertical division represent...

Page 71: ...ical 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 w...

Page 72: ...ical DC output voltage waveform Note the gap in the waveform One output diode was disconnected to simulate an open diode Each vertical division repre sents 50 volts and that each horizon tal division...

Page 73: ...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 trou bleshooting assistance...

Page 74: ...marked on the brush holder beside the termi nal for the red wire 5 To change the brushes use the slot head screw driver to pop off the plastic retainer on the back of the brush holder assembly 6 Remov...

Page 75: ...ure F 14 This will hold the brushes up so that you can eas ily install the holder 9 With the needle nose pliers reinstall the red and the black wires to the appropriate terminals on the brushes The re...

Page 76: ...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 216 383 2531 or 1 80...

Page 77: ...tted with a shake proof star washer under the screw head 8 To reinstall the rheostat replace each of the brass screws Place a shake proof star washer under the head insert the screw into the rheostat...

Page 78: ...cedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 93...

Page 79: ...he holder then slide it upward 6 Cut the tie wrap and snap the capacitor out of the assembly 7 Loosen the two screws on the top of the capacitor Leads 202B and 202 Red attach to the positive terminal...

Page 80: ...s or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WEL...

Page 81: ...r 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 4 Discharge the field capacitor by connecting the jumper wire clips o...

Page 82: ...located diagonally across from the positive terminal The Blue lead 7A is attached to one AC ter minal Leads 9A and 9B are piggy backed to the other AC terminal 8 Mount the field diode bridge using th...

Page 83: ...r 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 trou bleshooting assistance befor...

Page 84: ...that hold the control panel in place Carefully move the control panel aside as far as the leads will allow 4 Locate and remove the two molex plugs connected to the idler P C board See Figure F 19 5 W...

Page 85: ...his manual 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 trou bleshooting...

Page 86: ...round 7 Carefully lift up and remove the output rec tifier bridge assembly 8 Reassembly Refer to the Wiring Diagram for proper connections to the positive and negative sides of the rectifier assembly...

Page 87: ...nued 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 th...

Page 88: ...on you do not 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 proc...

Page 89: ...TE The two thread forming screws with shake proof lock washers are used in the two holes nearest the engine 7 With the 5 16 nut driver remove the one sheet metal screw that holds the choke assembly to...

Page 90: ...mounting screws that hold the output choke in place NOTE The two thread forming screws with shake proof lock washers are used in the two holes nearest the engine 20 With the 9 16 wrench install the h...

Page 91: ...nician in removing the stator and or rotor for main tenance or replacement of either component MATERIALS NEEDED Lincoln Electric Rotor Removal Kit S20925 FOR ROTOR REMOVAL ONLY 5 16 nut driver 1 2 soc...

Page 92: ...e current transformer 9 Remove the green ground lead GND C from the wiring harness loom 10 With the slot head screw driver remove leads 201A and 202B from the field capacitor It may be necessary to cu...

Page 93: ...lit ring lock washer under the head and a shake proof star washer on the nut side The bolts must point toward the engine for reassembly 16 Lift up the stator and slide out the support bracket The engi...

Page 94: ...into the rotor shaft until it bottoms out on the thru bolt 5 With an impact wrench tighten the reverse thread bolt until the rotor pops off the engine crankshaft If an impact wrench is not available...

Page 95: ...hen rotate the shaft 180 degrees and measure again If the gauge does not clear loosen the four end bracket thru bolts reposition the end bracket retighten the bolts and recheck the air gap Repeat unti...

Page 96: ...EMOVAL 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 20 Replace...

Page 97: ...cal components ENGINE OUTPUT No Load RPM Load RPM Maximum Speed 3800 3500 Minimum Speed 3700 3300 WELDER GENERATOR OUTPUT1 Output Control Field Volts Field Amps Open Circuit Load Volts Load Amps Volts...

Page 98: ...NOTES WELDANPOWER 125 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 99: ...ing Diagram Weldanpower 125 Codes 10158 10160 G 2 M17578 Idler PC Board Schematic G 3 Dimension Print Weldanpower 125 G 4 Idler PC Board Components G 6 TABLE OF CONTENTS DIAGRAMS SECTION Return to Mas...

Page 100: ...5 3 7 CLEVELAND OHIO U S A 3 5 6 7 O I L L E V E L S W I T C H 1 5 2 0 8 2 0 4 WIRING DIAGRAM WELDANPOWER 125 1 4 1 4 I D L E R P C B O A R D C U R R E N T T R A N S 6 5 3 4 1 2 2 0 A 2 0 A B L K B L...

Page 101: ...UNLESS OTHERWISE SPECIFIED MFD CAPACITORS EARTH GROUND CONNECTION M M 17630 30 1 J1 FILE M17630_1BB RHEOSTAT INPUT 100V 1A Q4 8V COM COM 8V 10 5 4 1 COM 2 SNUBBER 204 J2 ELECTRICAL SYMBOLS PER E1537 M...

Page 102: ...TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DIAGRAMS G 4 G 4 WELDANPOWER 125 DIMENSION PRINT WELDANPOWER 125 A 2 0 0 0 5 0 8 R E F 2 1 1 3 5 3 7 R E F R 7 9...

Page 103: ...OTES G 5 G 5 WELDANPOWER 125 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 104: ...R27 R28 R29 IDLER C2 C6 Q2 C14 J1 J2 Q1 R30 R2 C1 D2 D4 D3 D1 D9 NOTE Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting PC Board repairs will inval...

Page 105: ...CEMO 022 50V 20 C8 CAPACITOR CD 05 600V 80 20 C11 CAPACITOR PEF 0 47 50V 10 CR1 RELAY SPDT 12VDC 155OHMS AG CDO D1 D2 D3 D4 D9 DIODE AXLDS 3A 600V 1N5406 D5 D10 D11 D13 DIODE AXLDS 1A 400V D6 D12 DIO...

Page 106: ...OTES G 8 G 8 WELDANPOWER 125 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...

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