Lincoln Electric WELDMARK 225 IM927 Operator's Manual

Lincoln electric welder user manual

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WELDMARK 225
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
I NSTAL L ,
OPERATE OR REPAI R THI S
EQUI PM ENT W I THOUT READ-
I NG THI S M ANUAL AND THE
SAFETY PRECAUTI ONS CON-
TAI NED THROUGHOUT. And,
most importantly, think before you
act and be careful.
R
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
RETURN TO MAIN MENU
For Machines with Code Number 11396
R
C
US
OPERATOR' S M ANUAL
WELDMARK 225
• Manufactured by Lincoln Electric Company •
Copyright © 2007 Lincoln Global Inc.
IM9 7
January, 2007

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Summary of Contents for Lincoln Electric WELDMARK 225 IM927

  • Page 1 OPERATOR’ S M ANUAL WELDMARK 225 • Manufactured by Lincoln Electric Company • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com RETURN TO MAIN MENU Copyright © 2007 Lincoln Global Inc.
  • Page 2: California Proposition 65 Warnings

    351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
  • Page 3 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.
  • Page 4 WELDING and CUTTING 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 materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 5 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.
  • Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
  • Page 7: Table Of Contents

    Auxiliary Power While Welding, Standby Power Connections ...A-8 Premises Wiring ...A-9 ________________________________________________________________________________ Operation...Section B Safety Precautions ...B-1 General Description...B-1 Welder Controls Function and Operation ...B-1 Polarity, Range and Control Switch...B-2 Start in/Shutdown Instructions ...B-3 Starting the Engine...B-3 Safety Precautions ...B-3 Stopping the Engine ...B-3 Break-In Period ...B-3...
  • Page 8: Installation

    Gasoline CH23S Engine. Aluminum Alloy with Cast Iron Liners, Electronic Ignition RATED OUTPUT @ 104°F (40°C) FOR WELDER RATED OUTPUT @ 104°F (40°C) FOR GENERATOR HEIGHT WIDTH 30.3 in. 19.1 in. 770 mm 485 mm 1. Output rating in watts is equivalent to volt - amperes at unity factor. Output voltage is within +/-10% at all loads up to rated capacity.
  • Page 9: Safety Precautions

    To prevent dangerous electric shock, other equip- ment to which this engine driven welder supplies power must: • be grounded to the frame of the welder using a grounded type plug, or be double insulated. Do not ground the machine to a pipe that carries explosive or combustible material.
  • Page 10: Vehicle Mounting

    Use caution as the electrolyte is a strong acid that can burn skin and damage eyes. ----------------------------------------------------------------------- This welder is shipped with the negative battery cable disconnected. Make sure that the Engine Switch is in the “STOP” position and attach the disconnected cable securely to the negative battery terminal before attempting to operate the machine.
  • Page 11: Welding Output Cables

    Listed below are copper cable sizes recommended for the rated current and duty cycle. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop.
  • Page 12: Location And Ventilation

    Also, locate the welder so that engine exhaust fumes are properly vented to an outside area.
  • Page 13: Welder Operation

    WELDER OPERATION WELDER OUTPUT • Maximum Open Circuit Voltage at 3700 RPM is 80 Volts RMS. • Duty Cycle is the percentage of time the load is being applied in a 10 minute period. For example, a 60% duty cycle represents 6 minutes of load and 4 minutes of no load in a 10 minute period.
  • Page 14 ELECTRICAL DEVICE USE WITH THE WELDMARK 225. Type Resistive Capacitive Inductive Capacitive/Inductive The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected INSTALLATION TABLE lll Common Electrical Devices Heaters, toasters, incandescent light bulbs, electric range, hot pan, skillet, coffee maker.
  • Page 15 AUXILIARY POWER WHILE WELDING Simultaneous welding and power loads are permitted by following Table I. The permissible currents shown assume that current is being drawn from either the 120V or 240V supply (not both at the same time). Also, the “Output Control” is set at “10” for maximum auxiliary power.
  • Page 16: Premises Wiring

    CONNECTION OF WELDMARK 225 TO PREMISES WIRING 240 VOLT POWER 240 Volt 60 Hz. COMPANY 3-Wire Service METER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. 50 AMP, 120/240 VOLT PLUG NEMA TYPE 14-50 50 AMP, 120/240 VOLT RECEPTACLE...
  • Page 17: Operation

    • Insulate yourself from work and ground • Always wear dry insulating gloves. • Always operate the welder with the hinged door closed and the side panels in place. • Read carefully the Safety Precautions page before operating this machine. Always follow...
  • Page 18: Polarity Switch

    “ The “Range” switch is used to select one of three amperage ranges with generous overlap for Stick/TIG welding, or one Wire Feed welding range. Process STICK/TIG (constant current) (3 range settings) WIRE FEED (constant voltage) (one range setting) Never change the “RANGE” Switch setting while welding.
  • Page 19: Start In/Shutdown Instructions

    STARTING/SHUTDOWN INSTRUCTIONS STARTING 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. •...
  • Page 20: Welding Process

    WELDING PROCESS For any electrodes the procedures should be kept within the rating of the machine. For electrode infor- mation see the appropriate Lincoln publication. STICK (CONSTANT CURRENT) WELDING Connect welding cables to the "TO WORK” and "ELECTRODE” studs. Start the engine. Set the "Polarity”...
  • Page 21: Summary Of Welding Processes

    CONTROL PROCESS STICK WIRE FEED, LN-15 ACROSS the ARC (has internal contactor) WIRE FEED, LN-25 WITH INTERNAL CONTACTOR TIG, TIG MODULE WITH WITH CONTACTOR KIT CONTROL CABLE, & ARC START SWITCH OPERATION SUMMARY OF WELDING PROCESSES ELECTRODE CABLE IDLE WHEN NOT USED MODE WELDING AUTO AUTO Cold AUTO...
  • Page 22: Accessories

    OPTIONAL EQUIPMENT 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 &...
  • Page 23: Recommended Equipment

    RECOMMENDED EQUIPMENT STICK K704 or K875 Accessory Kit (See Accessory page C-1 for items included in Kit.) WIRE FEED K449 LN-25 - Includes internal contactor for across the arc operation (no control cable). Provides “cold” electrode until gun trigger is pressed. Includes gas solenoid.
  • Page 24: Maintenance

    SAFETY PRECAUTIONS 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 mainte- nance requiring their removal is complete.
  • Page 25: Oil Filter Change

    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 con- tainer to be sure it includes the letters SG or SH. SAE 10W-30 is recommended for general, all-tempera- ture use, -5 F to 104 F (-20 C to 40 C).
  • Page 26: Engine Maintenance Parts

    • CONNECTING A BATTERY CHARGER - Remove battery from welder by dis- connecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated.
  • Page 27: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE 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.
  • Page 28 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. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
  • Page 29 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. Engine does not develop full power. Engine is hard to start. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
  • Page 30 WIRING DIAGRAMS WELDMARK 225...
  • Page 31 DIAGRAMS WELDMARK 225...
  • Page 32: Dimension Print

    DIMENSION PRINT WELDMARK 225...
  • Page 33 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
  • Page 34 Spanish PRECAUCION French ATTENTION German WARNUNG Portuguese Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 35 WELDMARK 225 • Manufactured by Lincoln Electric Company • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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Weldmark 225

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