Lincoln Electric 125 Service Manual
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Lincoln Electric 125 Service Manual

Lincoln Electric 125 Service Manual

Wire feeder welder
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WIRE FEEDER WELDER (125, 140 MODELS)
For use with machines having Code Numbers:
11631, 11632, 11633, 11634,
11635, 11636, 11637, 11638 &
11639
SERVICE MANUAL
SVM227-A
| Issue D ate 13-Jan
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.

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  • Page 1 NOTE: This manual will cover most of the troubleshooting and repair procedures for the code numbers listed. Some variances may exist when troubleshooting/repairing later code numbers. WIRE FEEDER WELDER (125, 140 MODELS) For use with machines having Code Numbers: 11631, 11632, 11633, 11634, 11635, 11636, 11637, 11638 &...
  • Page 2 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 (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer. 5.f. Also see item 1.b. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 4 During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma 022690-9101. 6.j. Do not use a welding power source for pipe thawing. Refer to http://www.lincolnelectric.com/safety for additional safety information. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 5 4. Garder tous les couvercles et dispositifs de sûreté à leur place. talons sans revers, et chaussures montantes. 5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 6 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
  • Page 7 Screening of the entire welding installation may be considered for special applica- tions. 1 _________________________ 1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) product standard for arc welding equipment.” WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 8 Parts Manual ..........P-653 Wire Feeder Welders P-202-E.2 Mag 100L Gun Cable WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 9 Identify And Locate Components For 125 Amp Unit ....... . .
  • Page 10 INSTALLATION TECHNICAL SPECIFICATIONS: 125 Amp units (K2479-1, K2513-1, K2696-1, K2699-1, K2785-1) INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current 120 V / 60 Hz 20 Amps @ rated output RATED OUTPUT Duty Cycle Current Voltage at Rated Amperes 20% Duty Cycle...
  • Page 11 ELECTRIC SHOCK can kill. STACKING • Only qualified personnel should perform this installation. 125 AMP and 140 AMP Compact Wire Welders cannot • Only personnel that have read be stacked. and understood the machine’s Operating Manual should install TILTING and operate this equipment.
  • Page 12 INSTALLATION IDENTIFY AND LOCATE COMPONENTS for 125 AMP UNIT • .025 -.035 Dual Groove Drive Roll (Factory • Wire Feeder Welder installed .035 groove ready for flux-cored process) .025 GROOVE .035 GROOVE • Black Gun Nozzle (Installed on Welding Gun) •...
  • Page 13 • CD REGULATOR 2" SPINDLE ADAPTER (FOR 8" REEL OF WIRE) • Spool of .035 diameter NR-211MP GAS HOSE Innershield Flux-cored Wire IM10049 "INSTRUCTION • Spool of .025 diameter Super Arc L-56 MIG Wire MANUAL" WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 14 NOTES WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 15: Table Of Contents

    Setting Up and Making A Aluminum Weld Using Spool Gun ........B-12 WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 16: Operation

    COMMON WELDING ABBREVIA- • Wear eye, ear and body protec- tion. TIONS GMAW (MIG) Observe all safety information throughout this manual. • Gas Metal Arc Welding ------------------------------------------------------------ FCAW (INNERSHIELD OR OUTERSHIELD) • Flux Core Arc Welding WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 17: Controls And Settings

    6. WORK CLAMP & CABLE – Clamps to the work piece being welded and completes the electrical welding circuit. 7. GUN TRIGGER CONNECTOR RECEPTACLE – Plug the 4 pin gun trigger connector into this recep- tacle. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 18 MAGNUM 100SG / MAGNUM 100L SWITCH - The spool gun switch is available on 140 Amp machines SWITCH only. The Magnum 100SG Spool Gun can be pur- chased at authorized retailers. The part number is K2532-1. MAGNUM 100SG MAGNUM 100L WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 19 Press to reset. 13. GAS INLET – Shielding gas connects to this inlet (This is not available on 125 Amp Unit.) SETTING UP AND MAKING A FLUx-CORED WELD WITH 125AMP OR 140AMP MACHINES A.
  • Page 20 .035”(0.9mm) NR-211MP flux-cored wire. 5. Carefully unwind and straighten the first six inches of welding wire from the spool. Do not let the end of the wire go to prevent the wire from unspooling. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 21 Contact Tip welding wire set the voltage and the wire feed INSTALL BLACK NOZZLE speed per the procedure decal attached to the inside of the wire drive compartment door. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 22 FEMALE END MALE END 75/25 100% MIXES 4. Brass gun nozzle. (REQUIRES ADAPTER SOLD SEPARATELY) 5. Welding Gun. * 125 Amp Units can not be upgraded for MIG welding. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 23 BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUTLET WHEN “CRACKING” THE VALVE. Never stand directly in front of or behind the flow regulator when opening the cylinder valve. Always stand to one side. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 24 5. Carefully unwind and straighten the first six inches of welding wire from the spool. Hold onto the wire until the Pivot Arm assembly and Tension Arm are DRIVE ROLL locked in place. This will prevent the wire from unspooling. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 25 STICKOUT INSTALL .025 CONTACT TIP 3/8"(9.5mm) speed per the procedure decal attached to the from the Brass Nozzle inside of the wire drive compartment door. INSTALL BRASS NOZZLE WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 26: Setting Up And Making A Aluminum Weld Using Spool Gun

    MAGNUM 100SG MAGNUM 100L FIGURE B.20 THUMB SCREW FOR 6. Turn machine on and make weld per recommended CONNECTING THE settings on Procedure Decal inside machine door. MAGNUM 100L GUN OR MAGNUM 100SG SPOOL GUN. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 27 Connecting The Gun To The Welding Machine ..........C-11 WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 28: Accessories

    Protect your machine when not in use. Made from attractive red canvas that is flame retardant, mildew resistant and water repellent. Includes a convenient side pocket to hold welding gun. For additional Optional and Miscellaneous Parts (See Parts Pages) WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 29 1/4"-20 X 1/2" Hex Head Cap Screw (2 Required) 1/4"-20 X 1" Thread Forming Screw (1 Required) 1/4"-20 X 1/2" Hex Head Cap Screw (2 Required) 3-3/4" (95.3mm) 9/32"(7.1mm) DRILL 3 PLACES (204.8mm) 8-1/16" (96.8mm) 3-13/32" 3-11/16" (93.7mm) 4"(102mm) 16"(406.4mm) WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 30 1/4"-20 X 1/2" Hex Head Cap Screw (2 Required) 1/4"-20 X 1" Thread Forming Screw (1 Required) 1/4"-20 Flange Nut (2 Required) 9/32"(7.1mm) DRILL 3 PLACES 1-1/4"(31.8mm) 7-9/16"(192.1mm) 3-3/16"(81mm) 2-15/16"(74.6mm) 1-1/2"(38.1mm) 13-1/2"(342.9mm) WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 31: Technical Specifications - Magnum 100Sg Spool Gun K52321

    5356 wire; wire spool not installed. 2. One spool of 0.035 aluminum alloy 4043 wire. 3. Three S19726-3 contact tips. 4. One instruction manual (IM913). 5. One M21182 electrical harness with toggle switch. WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 32: Locating Spool Gun Components And Features

    FIGURE C.2 7. Integrated Single-Piece Cable: The Magnum design provides neat and clean appearance; simplifies cable management and reduces entanglements. 8. Standard Durable Strain Relief Clamp. 9. Three Captive Hex Nuts. Right Side View WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 33 10. Conical spring (not shown) serves as the spool Trigger. (See Maintenance Section for more brake (use only with aluminum alloy 5356). details) 6. Welding Power and Shielding Gas Machine connec- tion (Sealed with 2 o-rings). WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 34: Recommended Welding Machines

    2. The Conical Spring is used as the spool brake only when feeding the stronger and harder aluminum alloy 5356. The Conical Spring must be removed from the spool gun whenever using the softer alu- minum alloy 4043. WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 35: Loading Aluminum Wire

    6. Gently pull open the idle roll assembly to expose the drive roll groove. 3. Select wire alloy and diameter needed. Alloy 4043 and 0.035 wire size shown. Remove packaging and data sheet from wire spool. FIGURE C.10 FIGURE C.7 Size Alloy WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 36 There should only be 1 to 2 lbs. of resistance. If force is greater than 2 lbs. wire is binding in the gun (See Troubleshooting FIGURE C.13 Guide). FIGURE C.16 WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 37: Connecting The Gun To The Welding Machine

    3: finger-tighten locking knob. 4: check for uniform fit all around cover. FIGURE C.18 4. Check that the cable connector’s end is flush with insulator at A. Tighten gun locking knob (B) onto cable connector. FIGURE C.20 WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 38 NOTES C-12 C-12 WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 39 Major Component Location .............D-4 WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 40: Maintenance

    (fixed) side of the adhering to the wall of the hole through the tip. WIRE FEEDER WELDERS (125 and 140 MODELS). 2. Replace worn contact tips as required. A variable or Take the unit to an authorized Lincoln Service Center if “hunting”...

  • Page 41: Overload Protection

    OVERLOAD PROTECTION Liner Trim Length Output Overload The WIRE FEEDER WELDERS (125 and 140 MOD- ELS) are equipped with a circuit breaker and a ther- mostat which protects the machine from damage if maximum output is exceeded. The circuit breaker but- ton will extend out when tripped.
  • Page 42 MAINTENANCE MAJOR COMPONENT LOCATIONS 1. Case Front Assembly 2. Wire Drive Assembly 3. Center Panel Assembly 125 Amp Machine 4. Center Panel Assembly 140 Amp Machine 5. Wraparound & Door Assembly WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 43 RECEPTACLE WIRE SPEED CONTROL WIRE FEED LINE MOTOR SWITCH WIRE DRIVE MOTOR & SOLENOID VOLTAGE NOT FOUND IN 125A MACHINE VOLTAGE RECTIFIER CONTROL – SWITCH OUTPUT TERMINALS MAIN TRANSFORMER RESISTOR AND OUTPUT CAPACITOR CHOKE WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 44 MIG or Flux-Core process. The 125 amp machines are rated for 90 amps, 19 volts, at 20% duty cycle. The 140 amp machines are rated for 90 amps, 19.5 volts, at a 20% duty cycle. The 125 amp machines are Flux-Core process only. All are...
  • Page 45 The fan motor is rated for the same AC Voltage as the welder and should run whenever the machine is Power Switch is turned ON. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 46 The resistor and capacitor is found in the 140 amp machines and is not needed in the 125 amp machines. Since the 125 amp machines are Flux-cored only machines using DC- polarity, filtering of this rectified DC voltage is not necessary.
  • Page 47 The control board also has an automatic protection cir- cuit, which shuts off the trigger circuit in the event of a wire drive motor overload. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 48 The compact wire feeder welders features an overload protection of the wire drive motor. If the motor becomes overloaded, the protection circuitry turns off the wire feed unit. To reset simply release and re-trig- ger. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 49 Retest and Repair ..............F-37 WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 50 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by 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. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 51: Troubleshooting And Repair

    Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- CAUTION er failure analysis.
  • Page 52 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 53 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 54 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 55 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 56 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 57 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 58 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 59: Case Cover Removal And Replacement Procedure

    CASE COVER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by 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.
  • Page 60 2. Using a 5/16” nutdriver, remove the nine hex- head screws from the top and left side of the machine. 3. Using a 5/16” nutdriver, remove the screw from the front that secures the plastic handle. See Figure F.1. WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 61: Gas Solenoid Test

    NOT APPLICABLE ON 125 AMP MACHINES WARNING Service and repair should be performed only by 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.
  • Page 62 TROUBLESHOOTING AND REPAIR F-14 F-14 GAS SOLENOID TEST (continued) NOT APPLICABLE ON 125 AMP MACHINES FIGURE F.2 – GAS SOLENOID LOCATION & LEADS Gas Solenoid Leads PROCEDURE 6. If the 6.5 VDC is missing or is low, check the 1. Remove input power to the machine.

  • Page 63: Wire Drive Motor Test

    WIRE DRIVE MOTOR TEST WARNING Service and repair should be performed only by 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.
  • Page 64 21 to 31 VDC at pins 4 and 5 at P3 on the control board ELECTRIC SHOCK can kill. on 140 amp machines, pins 4 and 11 on 125 • Have an electrician install and ser- amp machines. See Wiring Diagram.

  • Page 65: Main Transformer Test

    MAIN TRANSFORMER TEST WARNING Service and repair should be performed only by 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.
  • Page 66 • Have an electrician install and ser- vice this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts. Turn the machine OFF between each test. -------------------------------------------------------------- WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 67: Fan Motor Test

    FAN MOTOR TEST WARNING Service and repair should be performed only by 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.
  • Page 68 See Wiring Diagram. Turn the machine OFF between each test. -------------------------------------------------------------- 10. If the correct voltages are at the fan motor, pos- sible bad motor. WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 69: Typical Output Voltage Waveform - Machine Loaded

    5 milliseconds in time. Note: Scope probes connect at the machine output terminals. Positive probe to (+) terminal, negative probe to (-) terminal. SCOPE SETTINGS Volts/Div.....10V/Div. Horizontal Sweep ...20 ms/Div. Coupling......DC Trigger......Internal WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 70: Abnormal Open Circuit Voltage Waveform

    20 millisec- onds in time. Note: Scope probes connect at the machine output terminals. Positive probe to (+) terminal, negative probe to (-) terminal. SCOPE SETTINGS Volts/Div.....10V/Div. Horizontal Sweep ...20 ms/Div. Coupling......DC Trigger......Internal WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 71 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by 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.
  • Page 72 -------------------------------------------------------------- 2. Perform the Case Cover Removal Procedure. 3. Locate the Control Board. See Figure F.6. 4. Label and disconnect all plugs and leads con- nected to the Control Board. WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 73: Rectifier Removal And Replacement Procedure

    RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by 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.
  • Page 74 -------------------------------------------------------------- 3. Label and remove the leads going to the rectifi- 4. Using a 7/16” nutdriver, remove the two rectifier mounting bolts. See Figure F.7, take note of washer placement. WIRE FEEDER WELDERS (125, 140 MODELS)

  • Page 75: Transformer & Choke Assembly Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by 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.
  • Page 76 OFF at the fuse box before working on equipment. Do not touch electrically hot parts. -------------------------------------------------------------- 3. Perform the Rectifier Removal Procedure. 4. Label and remove the leads connected to the voltage control switch. See Figure F.8. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 77 CONTROL THREAD FORMING SCREWS TRANSFORMER AND CHOKE 5. Label and remove the leads connected to the capacitor (not applicable in the 125 Amp Machine). 6. Unplug the thermostat leads. 7. Remove the four thread forming screws on the case bottom. See Figure F.9.
  • Page 78 NOTES F-30 F-30 WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 79 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by 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.
  • Page 80 8. Remove the Wire Drive Motor and replace. See working on equipment. Do not Figure F.12. touch electrically hot parts. -------------------------------------------------------------- 3. Remove the gun and cable assembly from the machine. 4. Disconnect the power lead from the wire drive mount. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 81 FIGURE F.11 – 1/4” MOUNTING BOLTS LOCATION 1/4” BOLTS 9. Install the four phillips screws and the two 7/16” bolts previously and torque to 23 - 27 inch/lbs. FIGURE F.12 – WIRE DRIVE MOTOR REMOVAL WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 82 NOTES F-34 F-34 WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 83 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by 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.
  • Page 84 OFF at the fuse box before bolts. working on equipment. Do not touch electrically hot parts. -------------------------------------------------------------- 3. Locate Fan in Figure F.13 and the four mount- ing screws that hold the fan in Figure F.14. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 85 TROUBLESHOOTING AND REPAIR F-37 F-37 RETEST AFTER REPAIR (125 AMP UNITS) INPUT IDLE AMPS & WATTS Input Volts/Hertz Maximum Idle Amps Maximum Idle Watts 120/60 4.80 OPEN CIRCUIT VOLTAGE 23 - 33 VDC WIRE SPEED RANGE 50-500 in./min. (1.3-12.7 m/min) RETEST AFTER REPAIR (140 AMP UNITS) INPUT IDLE AMPS &...
  • Page 86 Schematic – Control Board - (G6781-1) ...........G-5 * NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-layered and are therefore considered to be unserviceable. Assembly drawings of these boards are no longer provided. WIRE FEEDER WELDERS (125, 140 MODELS)
  • Page 87 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. WirE FEEDEr WELDEr (125, 140 mODELs)
  • Page 88 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. WirE FEEDEr WELDEr (125, 140 mODELs)
  • Page 89 MATERIAL APPROVAL PROJECT CRM40380 12/10/2010 INCH DO NOT SCALE THIS DRAWING APPROVED: DISPOSITION: DATE: NUMBER: NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. WirE FEEDEr WELDEr (125, 140 mODELs)
  • Page 90 PROJECT 6781-1C1 A.01 --------- 5040624 APPROVED: 6-28-2010 HAVING A COMMON CODE NUMBER. DISPOSITION: DATE: NUMBER: NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. WirE FEEDEr WELDEr (125, 140 mODELs)

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