Lincoln Electric WELDANPOWER 125 IM530-C Operator's Manual

Lincoln electric welder user manual

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IM530-C
Weldanpower 125
®
September, 2006
For use with Equipment having Code Numbers : 10158, 10160, 11183, 11406
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper
installation
...
and
thoughtful operation on your part.
DO NOT INSTALL, OPERATE
OR REPAIR THIS EQUIPMENT
WITHOUT
READING
THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR'S MANUAL
Copyright © 2006 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Summary of Contents for Lincoln Electric WELDANPOWER 125 IM530-C

  • Page 1 RETURN TO MAIN MENU IM530-C Weldanpower 125 ® September, 2006 For use with Equipment having Code Numbers : 10158, 10160, 11183, 11406 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...
  • Page 2: Safety

    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

    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 SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • 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 suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 The code number is especially important when identifying the correct replacement parts. - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
  • Page 7: Table Of Contents

    Safety ...i-iv Installation...1-7 Technical Specifications ...1 Input - Gasoline Engine Rated Output - Welder Output - Welder and Generator Physical Dimensions Location and Ventilation...2 Storing...2 Stacking ...3 Tilting ...3 Lifting ...3 Pre-Operation Engine Service ...3 Electrical Output Connections...4 Machine Grounding...5 Plugs and Hand Held Equipment...6...
  • Page 8: Installation

    EX 27 3600 RPM Aluminum Block /w Codes Cast Iron Sleeve (11183, 11406) Duty Cycle OUTPUT - WELDER AND GENERATOR Welding Ranges 50 - 125 Amps DC Height 21.13 in. 530 mm OPERATING TEMPERATURE RANGE 0° F TO 104° F (-18° C TO 40° C)
  • Page 9: Location And Ventilation

    Read this entire installation section before you start installation. Safety Precautions WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.
  • Page 10: Stacking

    STACKING Weldanpower 125 machines CANNOT be stacked. TILTING Place the machine on a secure, level surface whenever 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 position for best performance.
  • Page 11: Electrical Output Connections

    Table A.1 lists recommended cable sizes and lengths for rated current and duty cycle. Length refers to the distance from the welder to the work and back to the welder. Cable diameters are increased for long cable lengths to reduce voltage drops.
  • Page 12: Machine Grounding

    • Do not cross welding cables at output stud connection. Keep isolated and separate from one another. ------------------------------------------------------------------------ Lincoln Electric offers a welding accessory kit with #6 welding cables. See the ACCESSORIES section of this manual for more information. For more information on welding , see WELDING OPERATION in the OPERATION section of this manual.
  • Page 13: Plugs And Hand Held Equipment

    PLUGS AND HAND HELD EQUIPMENT For further protection against electric shock, any electrical equipment connected to the generator receptacles must use a three-blade, grounded type plug or an Underwriter’s Laboratories (UL) approved double insulated tool with a two blade plug. WARNING Never operate this machine with damaged or defective cords.
  • Page 14: Electrical Device Use With The Weldanpower 125

    Capacitive / Inductive Computers, high resolution TV sets, complicated electrical equipment. The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to a Weldanpower 125. WELDANPOWER 125 INSTALLATION CAUTION TABLE A.2 –...
  • Page 15 NOTES – – WELDANPOWER 125...
  • Page 16: Operation

    OPERATING INSTRUCTIONS General Warnings SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous.
  • Page 17: Graphic Symbols

    OPERATION GRAPHIC SYMBOLS USED ON THIS EQUIPMENT OR IN THIS MANUAL WARNING / CHOKE CAUTION AIR CLEANER CIRCUIT FUEL BREAKER WORK CLAMP GROUND (AUXILIARY POWER) For Codes 10158, 10160 only. ELECTRODE FAST WELDING ARC SLOW WELDANPOWER 125 – –...
  • Page 18: Product Description

    The machine is capable of higher duty cycles at lower output currents. For example, you can load the welder to 100 amps for six minutes out of ten for a 60% duty cycle. The current is continuously variable from 50 to 125 amps DC.
  • Page 19: Controls And Settings

    CONTROLS AND SETTINGS All welder/generator controls are located on the FIGURE B.1 and B.1a – OUTPUT PANEL CONTROLS FIGURE B.1 HOURS AMPS AMPS AMPS AMPS AMPS AMPS IDLER AMPS AMPS WARNING WARNING WELDANPOWER 125 WELDANPOWER 125 ELECTRODE SELECTION GUIDE ELECTRODE SELECTION GUIDE (For Codes 10158, 10160) 1.
  • Page 20: Engine Operation

    ENGINE OPERATION Engine Control Function/Operation Rocker “Run/Stop” Switch (For Codes 10158, 10160 Only) The two position “Run/Stop” switch is marked “I” and “O” on the red rocker and is located on the rear of the engine. In the run (I) position, the engine ignition circuit is energized, and the engine can be started by pulling the recoil rope starter.
  • Page 21: Welding Operation

    Break-in Period It is normal for any engine to use larger quantities of oil until break-in is accomplished. Check the oil level twice a day during the break-in period (about 50 running hours). Change the oil after the first 5 hours of operation.
  • Page 22: Generator Operation

    The Weldanpower 125 generator power can be used to supply up to 4,250 watts continuous input power to a Lincoln Wire Feeder/Welder. The Wire Feeder/ Welder is equipped with all the supplies needed for Flux-Cored Arc Welding (FCAW). Also some Wire Feeder/Welders come...
  • Page 23: Electrode Selection Guide

    AUXILIARY POWER OPERATION WARNING Be sure that any electrical equipment plugged into the generator AC power receptacles can withstand a ±10% voltage and a ±5% frequency variation. Some electronic devices cannot be powered by the WELDANPOWER 125. Refer to Table A.2, ELECTRICAL DEVICE WELDANPOWER 125, in the INSTALLATION section...
  • Page 24: Generator Power Applications

    *Submersible Pump - 1 HP *Sump Pump Toaster Weed Trimmer Lincoln Wire Feeder/Welder NOTES: Wattages listed are approximate. Check your equipment for actual wattage. Equipment with unusually high *START-UP WATTS are listed. For start-up of other equipment that uses a motor, listed in the table, multiply RUNNING WATTS by 2.
  • Page 25: Accessories

    OPTIONS/ACCESSORIES The following options/accessories are available for your WELDANPOWER 125 from your local Lincoln Distributor: Accessory Kit (K875) – Includes the following: • Twenty feet (6.1 meters) of #6 AWG electrode cable with lug. • Fifteen feet (4.6 meters) of #6 work cable with lugs. •...
  • Page 26: Maintenance

    SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. •...
  • Page 27 Do not attempt to polish slip rings while engine is running. ------------------------------------------------------------------------ Hardware Both English and Metric fasteners are used in this welder. MAINTENANCE Engine Maintenance Parts (For Codes 10158, 10160) Air Filter Element Air Filter Pre-Cleaner...
  • Page 28: Troubleshooting

    How To Use Troubleshooting Guide This Troubleshooting Guide is designed to be used by the machine Owner/Operator. 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, please observe all safety notes and precautions detailed in the Safety Section of this manual to avoid electrical shock or danger while troubleshooting this equipment.
  • Page 29: Troubleshooting Guide

    Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage is Evident. No generator power or welding output. Generator power is available but unit will not weld. Unit will weld but low or no generator power is available.
  • Page 30 MISADJUSTMENT(S) ENGINE PROBLEMS 1. Idler Switch on HIGH Idle. 2. Engine choke is not fully open. 3. External load on welder or auxiliary power. - Remove load. 4. Machine output is under load or idle switch in wrong position. 5. Idle solenoid does not pull in.
  • Page 31: Troubleshooting Guide

    Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) Engine runs erratically or stops running. Engine sputters but will not start. Recoil starter is hard to pull. Arc is erratic and “pops out”. 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 32: Wiring Diagram

    WIRING DIAGRAM WELDANPOWER 125 – –...
  • Page 33 WIRING DIAGRAM ENHANCED DIAGRAM WELDANPOWER 125 – –...
  • Page 34 WIRING DIAGRAM – – WELDANPOWER 125...
  • Page 35: Dimension Print

    DIMENSION PRINT – – WELDANPOWER 125...
  • Page 36 NOTES WELDANPOWER 125 – –...
  • Page 37 NOTES WELDANPOWER 125 – –...
  • Page 38 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ● – –...
  • Page 39 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● – – WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
  • Page 40 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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Weldanpower 125

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