Lincoln Electric SVM 113-A manual

SVM 113-A January , 1996 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PREC[...]

SAFETY i i FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ____________________________________[...]

SAFETY ii ii ARC RA YS can burn. 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. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

SAFETY iii iii FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recommendations. 8.c. Ground the equipment in accordance with the U.S. Nati[...]

SAFETY iv iv 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 suiv- antes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits [...]

v v WELDANPOWER 125 Page Safety .................................................................................................................................................i-iv Installation ............................................................................................................................. Section A T echnical Specific[...]

T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 WELDANPOWER 125 Installation T echnical Specifications .............................................................................................................A-2 Safety Precautions .............................................................................................[...]

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 INST ALLA TION A-2 A-2 WELDANPOWER 125 TECHNICAL SPECIFICA TIONS - WELDANPOWER 125 INPUT - GASOLINE ENGINE Manufacturer Description Speed Displacement Ignition Capacities Briggs [...]

Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly r ead all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and maintenance instructions; and parts lis[...]

ST ACKING WELDANPOWER 125 machines CANNOT be stacked. TIL TING Place the machine on a secure, level surface whenev- er you use it or store it. Any surfaces you place it on other than the ground must be firm, non-skid, and structurally sound. The gasoline engine is designed to run in a level posi- tion for best performance. It can operate at an angl[...]

ELECTRICAL OUTPUT CONNECTIONS See Figure A.1 for the location of the curr ent control dial, weld output terminals, ground stud, cir cuit break- ers, 230 and 115 volt receptacles. WELDING CABLE CONNECTIONS Cable Size and Length Be sure to use welding cables that ar e large enough. The correct size and length becomes especially impor- tant when you a[...]

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 INST ALLA TION A-6 A-6 WELDANPOWER 125 Cable Installation Install the welding cables to your WELDANPOWER 125 as follows. See Figure A.1 for the location of parts. 1. The gasoline[...]

PREMISES WIRING The WELDANPOWER 125 three-wir e, grounded neu- tral 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 “hardwir ed” to the [...]

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 INST ALLA TION A-8 A-8 WELDANPOWER 125 Certain Electrical devices cannot be powered by the WELDANPOWER 125. See T able A.2. T ABLE A.2 ELECTRICAL DEVICE USE WITH THE WELDANPOWER [...]

Section B-1 Section B-1 WELDANPOWER 125 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Instructions ....................................................................................................[...]

OPERA TING INSTRUCTIONS Read and understand this entire section befor e oper- ating your WELDANPOWER 125. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly r ead all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and m[...]

RECOMMENDED APPLICA TIONS WELDER The WELDANPOWER 125 provides excellent constant current DC welding output for stick (SMA W) welding and DC TIG welding using the “scratch” starting tech- nique. THE K903 TIG Module can be added as an option to provide high fr equency starting. For more details on using the machine as a welder , see WELD- ING OPE[...]

WELDER/GENERA TOR CONTROLS See Figure B.1 for the location of the following fea- tures: 1. CURRENT CONTROL DIAL: Adjusts continuous current output. The amperages on the dial corr e- spond to the average amperages needed for spe- cific Lincoln welder rods. 2. ELECTRODE SELECTION GUIDE: Provides r ec- ommended electrode type, size, and welder out- pu[...]

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 OPERA TION B-5 B-5 WELDANPOWER 125 FIGURE B.2 – GASOLINE ENGINE CONTROLS 1. FUEL SHUT -OFF V AL VE 2. FUEL T ANK AND CAP 3. MUFFLER 4. STOP SWITCH/OIL GARD ® LIGHT 5. AIR CLEA[...]

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 alr eady set. DO NOT ADJUST THE AIR MIXTURE WITHOUT FOL- LOWING THE PROCEDURES OUTLINED BY BRIGGS & STRA TTON. 8. RECOIL ST ARTER: Manual, rope-type starter . The handle position [...]

FIGURE B.3 FUEL SHUT -OFF AND CHOKE CONTROL 3. Set the Idler Control switch to the “AUTOMA TIC” position. See Figure B.4. 4. Place the engine stop switch in the “RUN” position. See Figure B.4. 5. Pull slightly on the recoil starter handle until resis- tance is felt. FIGURE B.4 IDLER CONTROL AND STOP SWITCH 6. Pull the starter cord rapidly .[...]

BREAK-IN PERIOD 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. Check the oil frequently during br eak-in. Change the oil after the first 5 hours of operation. For more details, see the Maintenance section of this manual. LOW OIL SENSING [...]

TO USE THE WELDANPOWER 125 FOR WELD- ING: 1. Remove the flange nuts from the weld output ter- minals 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 ar e tight. 2. Select the appropriate electr ode. See T able B.2, Electrode Selection Guide . [...]

CURRENT RANGE (AMPS) AWS ELECTRODE CLASSIFICA TION ELECTRODE TYPE POLARITY 3/32 SIZE 1/8 SIZE 5/32 SIZE 6010 FLEETWELD® 5P + 50-75 75-125 - 6011 FLEETWELD® 35 + 50-75 70-110 80-125 6011 FLEETWELD® 180 + 50-80 55-110 105-125 6013 FLEETWELD® 37 ± 70-95 100-125 - 7018 JETWELD® LH-70 + 70-100 90-125 - 7018 JETWELD® LH-73 + 65-85 90-125 - 308-16 [...]

AUXILIAR Y POWER 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 power ed by the WEL- DANPOWER 125. Refer to T able A.2, ELECTRICAL DEVICE USE WITH THE WELDANPOWER 125, in the INST ALLA TION section of this manu[...]

T ABLE B.3 GENERA TOR POWER APPLICA TIONS Suggested Power Applications Running W atts *Start-up W atts *Air Compressor - 3/4 HP 1,250 3,100 - 5,000 *Airless Sprayer - 1/3 HP 600 1,500 - 2,400 Chain Saw 1,200 Circular Saw 1,200 Coffee Maker 1,000 *Deep Freezer 500 750 - 2,000 *Electric Motor - 1 HP 1,000 2,500 - 4,000 Electric Range (1 element) 1,50[...]

T ABLE OF CONTENTS -ACCESSORIES- Accessories ........................................................................................................................... Section C Options/Accessories...................................................................................................................C-2 Lincoln Electric Accessories ....[...]

OPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIES The following options/accessories are available for your WELDANPOWER 125 from your local Lincoln Distributor . Power Plug Kit (K802-U) – Provides thr ee plugs, two for the 115 volt duplex receptacle and one for the 230 volt receptacle. (Or der Power Plug Kit K802-T for the CSA model.) Accessory Set[...]

T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Routine and Periodic Maintenance ............................................................................................D-2 Engine Maintenance .........................[...]

SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T ur n the engine off before working inside the machine. • Remove guar ds only when necessary to perform maintenance and replace them when the mainte- nance requiring their r emoval is complete. • If guards ar e missing from the machine, get r eplac[...]

AIR CLEANER: With normal operating conditions, the maintenance schedule for cleaning and re-oiling the foam pr e-filter is every 25 hours and replacement of the air cleaner filter element every 100 hours. More fr equent servicing is required with dusty operat- ing conditions. Do not use petroleum solvents such as ker osene to clean the cartridge. T[...]

CLEAN OR REPLACE SP ARK PLUG: Clean or replace the spark plug after every 100 hours of opera- tion 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. W ash the plug with a commercial solvent. After cleaning or when installing a new spark[...]

T ABLE D.2 – ENGINE MAINTENANCE P ARTS Part Part Number OIL FIL TER NONE SP ARK PLUG (ST ANDARD) B&S 492167 SP ARK PLUG (RESISTOR) B&S 491055 CHAMPION RC12YC AIR CLEANER CARTRIDGE B&S 710266 (CAN BE CLEANED AND REUSED) AIR PRE-CLEANER B&S 710268 (AS NEEDED) (CAN BE CLEANED AND REUSED) MAINTENANCE D-5 D-5 WELDANPOWER 125 Return to [...]

MAINTENANCE D-6 D-6 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 FIGURE D.6 – MAJOR COMPONENT LOCA TIONS 1. CRADLE ASSEMBL Y 2. ROTOR, BLOWER, AND BEARING ASSEMBL Y 3. ST A TOR ASSEMBL Y 4. BRUSH AND BRUSH[...]

Section E-1 Section E-1 T ABLE OF CONTENTS -THEOR Y OF OPERA TION SECTION- Theory of Operation ............................................................................................................. Section E Power Supply Operation ..............................................................................................E-2 - E-3 Engine, [...]

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 OPERA TION E-2 E-2 WELDANPOWER 125 FIGURE E.2 – ENGINE, EXCIT A TION, ROTOR AND ST A TOR NOTE: Unshaded areas of Block Logic Diagram ar e the subject of discussion. ENGINE, EXC[...]

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 OPERA TION E-3 E-3 WELDANPOWER 125 FIGURE E.3 – ROTOR FIELD FEEDBACK, AUXILIAR Y POWER AND ENGINE IDLE CONTROL NOTE: Unshaded areas of Block Logic Diagram ar e the subject of d[...]

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 OPERA TION E-4 E-4 WELDANPOWER 125 FIGURE E.4 – WELD WINDING, OUTPUT RECTIFIER AND CHOKE NOTE: Unshaded areas of Block Logic Diagram ar e the subject of discussion. WELD WINDIN[...]

Section F-1 Section F-1 WELDANPOWER 125 T roubleshooting & Repair Section ................................................................................. Section F How to Use T roubleshooting Guide ......................................................................................F-2 PC Board T roubleshooting Pr ocedures ..................[...]

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 HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may [...]

ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. T ur n the machine OFF before working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC board failur es. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting [...]

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 TROUBLESHOOTING & REP AIR F-4 F-4 WELDANPOWER 125 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do n[...]

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 TROUBLESHOOTING & REP AIR F-5 F-5 WELDANPOWER 125 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do n[...]

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 TROUBLESHOOTING & REP AIR F-6 F-6 WELDANPOWER 125 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do n[...]

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 TROUBLESHOOTING & REP AIR F-7 F-7 WELDANPOWER 125 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do n[...]

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 TROUBLESHOOTING & REP AIR F-8 F-8 WELDANPOWER 125 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do n[...]

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 TROUBLESHOOTING & REP AIR F-9 F-9 WELDANPOWER 125 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do n[...]

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 TROUBLESHOOTING & REP AIR F-10 F-10 WELDANPOWER 125 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do[...]

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 TROUBLESHOOTING & REP AIR F-11 F-11 WELDANPOWER 125 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do[...]

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 TROUBLESHOOTING & REP AIR F-12 F-12 WELDANPOWER 125 TROUBLESHOOTING & REP AIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CA[...]

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 TROUBLESHOOTING & REP AIR F-13 F-13 WELDANPOWER 125 ROTOR VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthoriz[...]

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 F-14 F-14 WELDANPOWER 125 ROTOR VOL T AGE TEST (continued) FIGURE F .1 - LOCA TION OF LEAD 202 FOR ROTOR VOL T AGE TEST LEAD 202 CONNECTION (TOP TERMINAL, CASE FRONT IN PLACE GRO[...]

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 ROTOR RESIST ANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in [...]

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 TROUBLESHOOTING & REP AIR F-16 F-16 WELDANPOWER 125 ROTOR RESIST ANCE TEST (continued) FIGURE F .2 – LOCA TION OF ROTOR SLIP RINGS - BRUSH HOLDER ASSEMBL Y REMOVED SLIP RIN[...]

TROUBLESHOOTING & REP AIR F-17 F-17 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 ROTOR RESIST ANCE TEST (continued) FIGURE F .3 – BRUSHES RET AINED WITH CABLE TIE CABLE TIE BRUSHES 9. Reinstall the bru[...]

TROUBLESHOOTING & REP AIR F-18 F-18 WELDANPOWER 125 OUTPUT RECTIFIER BRIDGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and t[...]

OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F .4 - OUTPUT RECTIFIER BRIDGE W2 W1 204 Strap 203 TEST PROCEDURE 1. Conduct this test with the gasoline engine OFF . 2. Remove the spark plug wire to pr event accidental engine kickback or starting. 3. With the 5/16" nut driver , remove the 8 sheet metal screws that hold the top cover to the con[...]

TROUBLESHOOTING & REP AIR F-20 F-20 WELDANPOWER 125 MAIN ST A TOR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid el[...]

MAIN ST A TOR TEST (continued) FIGURE F .5 - LOCA TION OF LEADS W1 AND W2 W2 W1 204 Strap 203 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 . 2. With the 5/16" nut driver and the 5/16" open end or box wrench, r emove the 6 sheet metal scr[...]

MAIN ST A TOR TEST (continued) FIGURE F .6 - MAIN ST A TOR MOLEX PLUG TEST POINTS FIGURE F .6 MAIN ST A TOR MOLEX PLUG TEST POINTS FIGURE F .7 DIODE BRIDGE LEAD ASSIGNMENTS 5. Locate the 6 pin molex type connector from the main stator . 6. Check for 240 - 260 V AC at leads #6A to #3A. See Figure F .6. Y ou may want to shut off the engine, insert th[...]

TROUBLESHOOTING & REP AIR F-23 F-23 WELDANPOWER 125 ROTOR “FLASHING” CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety [...]

ROTOR “FLASHING” CIRCUIT TEST (continued) FIGURE F .8 - BRUSH HOLDER LEADS 201A(-) AND 202B (+) Slip Rings 201A(-) 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 . 2. Locate and remove lead #201A fr om the brush holder . See Figure F .8 [...]

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 ROTOR “FLASHING” CIRCUIT TEST (continued) FIGURE F .10 - IDLER P .C. BOARD PIN ASSIGNMENTS MOVING P ARTS can injure. Keep away from moving parts. ENGINE EXHAUST can kill. Use[...]

TROUBLESHOOTING & REP AIR F-26 F-26 WELDANPOWER 125 ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety an[...]

ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F .11 - BLOWER P ADDLE MARKED FOR STROBE-T ACH METHOD Mark TEST PROCEDURE This test can be conducted by any of three methods. Str obe-tach Method: 1. Remove the spark plug wire to pr event accidental kickback or starting. 2. With the black or red marking pencil, place a mark on one of the blower pa[...]

ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F .12 - IDLE SPEED ADJUSTMENT SCREW LOCA TIONS 5. ADJUST HIGH IDLE: With the Idler Switch set on HIGH, the tach should read between 3700 and 3800 RPM. a. If the engine speed is above 3800 RPM, turn the High Idle Increase Speed screw counter -clockwise sev- eral turns. T ur n the High Idle Decrease [...]

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: 1. Plug the frequency counter into one of the 1[...]

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 ENGINE THROTTLE ADJUSTMENT TEST (continued) 4. ADJUST LOW IDLE: Using a piece of dowel rod or a long scr ew driver , push the governor arm back until the Carburetor Throttle Leve[...]

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 TROUBLESHOOTING & REP AIR F-31 F-31 WELDANPOWER 125 CH1 0 volts 5 ms 50 volts SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep.....5 ms/Div . Couplin[...]

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 TROUBLESHOOTING & REP AIR F-32 F-32 WELDANPOWER 125 SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep.....5 ms/Div . Coupling ........................[...]

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 TROUBLESHOOTING & REP AIR F-33 F-33 WELDANPOWER 125 CH1 0 volts 5 ms 20 volts This is the typical DC output voltage generated from a pr operly operating machine. Note that ea[...]

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 TROUBLESHOOTING & REP AIR F-34 F-34 WELDANPOWER 125 CH1 0 volts 5 ms 50 volts This is not the typical DC output voltage waveform. Note the “gap” in the waveform. One outp[...]

TROUBLESHOOTING & REP AIR F-35 F-35 WELDANPOWER 125 BRUSH REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and[...]

BRUSH REMOV AL AND REPLACEMENT (continued) FIGURE F .14 - BRUSHES RET AINED WITH CABLE TIE CABLE TIE BRUSHES PROCEDURE 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 fin- gernail. The cover will drop open on its bottom hinge. 3. With the 1/4”[...]

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 BRUSH REMOV AL AND REPLACEMENT (continued) PROCEDURE (continued) 8. T o reinstall the brush holder assembly , depress the spring-loaded brushes into the holder and slip a suitabl[...]

TROUBLESHOOTING & REP AIR F-38 F-38 WELDANPOWER 125 RHEOST A T REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safet[...]

RHEOST A T REMOV AL AND REPLACEMENT (continued) FIGURE F .15 - RHEOST A T REMOV AL PROCEDURE 1. Remove the spark plug wire. 2. 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. With the 5/16” nut driver and the 5/16” wrench, r emove the 6 screws that hold the cont[...]

TROUBLESHOOTING & REP AIR F-40 F-40 WELDANPOWER 125 FIELD CAP ACITOR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your[...]

FIELD CAP ACITOR REMOV AL AND REPLACEMENT (continued) FIGURE F .16 - DISCHARGING THE FIELD CAP ACITOR 201C 201B 201A (+) 202 202B (-) Attachment for Attachment for Jumper Capacitor Cable T ie PROCEDURE 1. Remove the engine spark plug wire. 2. With the 5/16” nut driver , remove the 8 sheet metal screws that hold the top cover to the control box. R[...]

TROUBLESHOOTING & REP AIR F-42 F-42 WELDANPOWER 125 FIELD DIODE BRIDGE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For yo[...]

FIELD DIODE BRIDGE REMOV AL AND REPLACEMENT (continued) FIGURE F .17 - DISCHARGING THE FIELD CAP ACITOR 201C 201B 201A (+) 202 202B (-) Attachment for Attachment for Jumper Capacitor Cable T ie PROCEDURE 1. Remove the engine spark plug wire. 2. With the 5/16” nut driver , remove the 8 sheet metal screws that hold the top cover to the control box.[...]

FIELD DIODE BRIDGE REMOV AL AND REPLACEMENT (continued) FIGURE F .18 - FIELD DIODE BRIDGE LOCA TION Feild Diode Bridge 5. The field diode bridge is mounted to the sheet metal just above the capacitor . See Figure F .18. Remove it using the slot head screw driver and the 11/32” wr ench. 6. With the needle nose pliers, gently remove the 7 wires fr [...]

TROUBLESHOOTING & REP AIR F-45 F-45 WELDANPOWER 125 IDLER PRINTED CIRCUIT BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty[...]

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 IDLER PRINTED CIRCUIT BOARD REMOV AL AND REPLACEMENT (continued) FIGURE F .19 - IDLER P .C. CIRCUIT BOARD PROCEDURE Before starting the following pr ocedure, r efer to the topic [...]

TROUBLESHOOTING & REP AIR F-47 F-47 WELDANPOWER 125 OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . F[...]

OUTPUT RECTIFIER BRIDGE REMOV AL AND REPLACEMENT (continued) FIGURE F .20 - OUTPUT RECTIFIER CONNECTIONS 203 W2 W1 204 PROCEDURE 1. Remove the engine spark plug wire to pr e- vent accidental kickback or starting. 2. With the 5/16" nut driver , remove the 8 sheet metal screws fr om the case top. 3. With the 7/16" wrench, r emove the heavy [...]

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 OUTPUT RECTIFIER BRIDGE REMOV AL 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[...]

TROUBLESHOOTING & REP AIR F-50 F-50 WELDANPOWER 125 OUTPUT CHOKE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your saf[...]

OUTPUT CHOKE REMOV AL AND REPLACEMENT (continued) FIGURE F .21 - OUTPUT CHOKE MOUNTING DET AILS PROCEDURE 1. Remove the engine spark plug wire to pr e- vent accidental kickback or starting. 2. With the 5/16" nut driver , remove the 8 sheet metal screws fr om the case top. 3. With the 5/16" nut driver and 5/16" wrench, remove the 6 sh[...]

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 OUTPUT CHOKE REMOV AL AND REPLACEMENT (continued) 14. Reassembly: Install the output choke assembly by setting it down into position. Fit the idler solenoid plunger into the sole[...]

TROUBLESHOOTING & REP AIR F-53 F-53 WELDANPOWER 125 ST A TOR/ROTOR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your s[...]

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 ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) ST A TOR REMOV AL PROCEDURE 1. Remove the engine spark plug wire to pr e- vent accidental kickback or starting. 2. Perform th[...]

ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .22 - ST A TOR END BRACKET SUPPORT AND THRU-BOL TS THRU- BOL TS THRU- BOL TS NUTS SUPPORT 13. Slide a short length of 2 X 4 under the engine to support it when the stator is removed. 14. With the 1/2" socket wrench, r emove the 2 nuts that hold the stator end bracket support. See Fi[...]

ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .23 - ROTOR WITH ST A TOR REMOVED ROTOR THRU-BOL T ROTOR REMOV AL PROCEDURE 1. T o remove the rotor , double check that the spark plug wire is disconnected. Y ou will be turning the rotor during this procedur e, and this could accidentally cause engine kickback. 2. With an impact wr ench[...]

ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) FIGURE F .24 - CHECKING ROTOR-ST A TOR AIR GAP ROTOR S TAT O R FEELER GAUGE 4. Install the end bracket. Slide it on and install the two top thru-bolts loosely to hold the end bracket for the next step. 5. Install the end bracket support. 6. Install the bottom two end bracket thru- bolts. 7. T ap [...]

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 ST A TOR/ROT OR REMOV AL AND REPLACEMENT (continued) 18. Install the output choke. Refer to the topic "OUTPUT CHOKE REMOV AL AND REPLACEMENT" in this section of the man[...]

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 TROUBLESHOOTING & REP AIR F-59 F-59 WELDANPOWER 125 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that r equires you to remove any me[...]

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[...]

Section G-1 Section G-1 WELDANPOWER 125 Diagrams Section ............................................................................................................ Section G Wiring Diagram W eldanpower 125 (Codes 10158 & 10160) ................................................G-2 M17578 Idler PC Board Schematic ................................[...]

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 DIAGRAMS G-2 G-2 WELDANPOWER 125 WIRING DIAGRAM — (CODE 10158 & 10160) D1 C1 ROTOR (+) (-) (+) (-) (+) (-) D2 (+) (-) R1 STATOR 115 VOLT CHOKE ENGINE WIRING MAG OUTPUT STUD[...]

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 DIAGRAMS G-3 G-3 WELDANPOWER 125 IDLER PC BOARD (M17578) SCHEMA TIC 1N4936 D12 1.50K R14 10K R23 50V .47 C11 5W 10V DZ3 1W 15V DZ4 51.1K R22 162 R18 10K R24 50V 0.1 C13 22.1K R25[...]

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 DIAGRAMS G-4 G-4 WELDANPOWER 125 DIMENSION PRINT — WELDANPOWER 125 A 20.00 508 REF. 21.13 537 REF. R 7.92 201 REF. 13.62 346 REF. 30.00 762 REF. LINCOLN ELECTRIC M17614[...]

NOTES 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[...]

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 DIAGRAMS G-6 G-6 WELDANPOWER 125 M17578 IDLER PC BOARD R17 R16 R10 R7 R6 R1 R4 R9 R8 R5 R3 R14 C3 C7 C9 C11 C8 D6 DZ2 DZ1 D5 X1 CR1 TP1 R15 R13 R11 Q3 M17578-1 WP125 R18 C5 R12 C[...]

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 DIAGRAMS G-7 G-7 WELDANPOWER 125 M17578 IDLER PC BOARD BILL OF MA TERIALS NOTE: Lincoln Electric assumes no responsibility for liabilities r esulting from board level tr oublesho[...]

NOTES 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[...]