Lincoln Electric WELDANPOWER SVM 113-A Service Manual
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Lincoln Electric WELDANPOWER SVM 113-A Service Manual

Lincoln Electric WELDANPOWER SVM 113-A Service Manual

Lincoln electric welder user manual
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SVM 113-A
RETURN TO MAIN INDEX
January, 1996
TM
WELDANPOWER 1 25
For use with machine code numbers 10158 and 10160
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED 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 subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100

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Summary of Contents for Lincoln Electric WELDANPOWER SVM 113-A

  • Page 1: Service Manual

    SVM 113-A RETURN TO MAIN INDEX January, 1996 WELDANPOWER 1 25 For use with machine code numbers 10158 and 10160 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

    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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.

  • Page 6: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety...i-iv Installation ...Section A Technical Specifications ...A-2 Safety Precautions...A-3 Location and Ventilation ...A-3 Pre-operation Engine Service ...A-4 Electrical Output Connections...A-5 Operation...Section B Safety Instructions ...B-2 General Description ...B-2 Recommended Applications ...B-3 Operational Features and Controls ...B-3 Design Features and Advantages...B-3 Welding Capability ...B-3 Limitations ...B-3...
  • Page 7 Section A-1 - INSTALLATION SECTION - Installation Technical Specifications ...A-2 Safety Precautions...A-3 Location and Ventilation ...A-3 Storing ...A-3 Stacking...A-4 Tilting ...A-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 Machine Grounding ...A-6...

  • Page 8: Installation

    ® air-cooled gasoline 9 HP @ 3600 RPM RATED OUTPUT - WELDER Duty Cycle 30% Duty Cycle 60% Duty Cycle OUTPUT - WELDER AND GENERATOR Welding Ranges 50 - 125 Amps Height 21.13 in. 530 mm INSTALLATION Speed Displacement 3400 RPM 18.06 cu.

  • Page 9: Safety Precautions

    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 the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and maintenance instructions;...

  • Page 10: Pre-Operation Engine Service

    STACKING WELDANPOWER 125 machines CANNOT be stacked. TILTING 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.

  • 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: Cable Installation

    • Do not cross the welding cables at the output termi- nal connection. Keep the cables isolated and sepa- rate from one another. Lincoln Electric offers a welding accessory kit with the properly specified welding cables. Accessories section of this manual for more informa- tion.

  • Page 13: Premises Wiring

    PREMISES WIRING The WELDANPOWER 125 three-wire, 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 “hardwired”...
  • Page 14 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 the WELDANPOWER 125. INSTALLATION CAUTION TABLE A.2 WELDANPOWER 125...

  • Page 15: Recommended Applications

    Operational Features and Controls ...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 Starting the Engine ...B-6 Starting the Engine ...B-6 Stopping the Engine ...B-7 Break-in Period ...B-8...

  • Page 16: Operation

    The WELDANPOWER 125 is a low-cost welder/gener- ator designed for home use and other non-commercial applications. As a welder it provides 125 amps of con- stant DC current for welding with DC stick electrodes and for DC TIG welding. A single dial provides contin- uous adjustment of welding output from 50 to 125 amps.

  • Page 17: Recommended Applications

    The WELDANPOWER 125 is rated 125 amps, 25 volts DC at 30% duty cycle on a ten-minute basis. This means that you can load the welder to 125 amps for three minutes out of every ten-minute period. The machine is capable of higher duty cycles at lower out- put currents.

  • Page 18: Controls And Settings

    CONTROLS AND SETTINGS All welder/generators controls are located on the Output Control Panel. Gasoline engine controls are mounted on the engine. See Figures B.1 and B.2 and the explanations that follow. FIGURE B.1 – OUTPUT PANEL CONTROLS 1. CURRENT CONTROL DIAL 2.

  • Page 19: Gasoline Engine Controls

    5. GROUND STUD: Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure. 6. 20 AMP CIRCUIT BREAKERS (2): Provide sepa- rate overload current protection for the 115 volt and 230 volt receptacles. 7.

  • Page 20: Engine Operation

    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 already set. DO NOT ADJUST THE AIR MIXTURE WITHOUT FOL- LOWING THE PROCEDURES OUTLINED BY BRIGGS &...

  • Page 21: Stopping The Engine

    FIGURE B.3 FUEL SHUT-OFF AND CHOKE CONTROL Fuel Shut-off Choke Controls 3. Set the Idler Control switch to the “AUTOMATIC” 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.

  • Page 22: Break-In Period

    • Keep away from moving parts. Only qualified personnel should install, use, or service this equipment. The WELDANPOWER 125 generator/welder can deliv- er from 50 to 125 amps of continuous welding output current. Output can be adjusted by setting the current control dial on the output control panel.
  • Page 23 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. Replace and tighten the flange nuts securely. Be sure the connections are tight. 2.
  • Page 24 B-10 CLASSIFICATION ELECTRODE TYPE 6010 FLEETWELD® 5P 6011 FLEETWELD® 35 6011 FLEETWELD® 180 6013 FLEETWELD® 37 7018 JETWELD® LH-70 7018 JETWELD® LH-73 308-16 STAINWELD® 308-16 ENi-Cl SOFTWELD® 99NI ABRASOWELD™ MATERIAL THICKNESS NOTES: The values listed are suggested settings. Actual setting may vary depending on individual preference and/or spe- cific application.

  • Page 25: Auxiliary Power Operation

    B-11 AUXILIARY POWER CAUTION 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 powered by the WEL- DANPOWER 125. Refer to Table A.2, ELECTRICAL DEVICE USE WITH THE WELDANPOWER 125, in the INSTALLATION section of this manual.
  • Page 26 *Sump Pump Toaster Weed Trimmer Lincoln 100 or 125 Amp 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 listed in the table, multiply RUNNING WATTS by 2.
  • Page 27 Section C-1 Section C-1 TABLE OF CONTENTS -ACCESSORIES- Accessories...Section C Options/Accessories...C-2 Lincoln Electric Accessories ...C-2 Briggs and Stratton Accessories ...C-2 WELDANPOWER 125...
  • Page 28 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 three plugs, two for the 115 volt duplex receptacle and one for the 230 volt receptacle. (Order Power Plug Kit K802-T for the CSA model.)

  • Page 29: Routine And Periodic Maintenance

    Maintenance ...Section D Routine and Periodic Maintenance ...D-2 Engine Maintenance...D-2 Welder/Generator Maintenance ...D-5 Major Component Locations ...D-6 TABLE OF CONTENTS -MAINTENANCE- WELDANPOWER 125...

  • Page 30: Safety Precautions

    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 mainte- nance requiring their removal is complete. •...
  • Page 31 AIR CLEANER: With normal operating conditions, the maintenance schedule for cleaning and re-oiling the foam pre-filter is every 25 hours and replacement of the air cleaner filter element every 100 hours. More frequent servicing is required with dusty operat- ing conditions. CAUTION Do not use petroleum solvents such as kerosene to clean the cartridge.
  • Page 32 CLEAN OR REPLACE SPARK 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.

  • Page 33: Welder/Generator Maintenance

    SPARK PLUG (RESISTOR) AIR CLEANER CARTRIDGE AIR PRE-CLEANER (AS NEEDED) WELDER/GENERATOR MAINTENANCE STORAGE: Store the WELDANPOWER 125 in clean, dry, protected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air. Do this at least once a week in particularly dirty areas.

  • Page 34: Major Component Locations

    FIGURE D.6 – MAJOR COMPONENT LOCATIONS 1. CRADLE ASSEMBLY 2. ROTOR, BLOWER, AND BEARING ASSEMBLY 3. STATOR ASSEMBLY 4. BRUSH AND BRUSH HOLDER ASSEMBLY 5. CONTROL BOX WELDED ASSEMBLY 6. OUTPUT RECTIFIER ASSEMBLY 7. OUTPUT TERMINAL ASSEMBLY 8. OUTPUT PANEL ASSEMBLY MAINTENANCE WELDANPOWER 125...
  • Page 35 Section E-1 -THEORY OF OPERATION SECTION- Theory of Operation ...Section E Power Supply Operation ...E-2 - E-3 Engine, Excitation, Rotor and Stator ...E-2 Rotor Field Feedback, Auxiliary Power and Engine Idle Control...E-3 Auxiliary Power Overcurrent Protection ...E-3 Weld Winding, Output Rectifier and Choke ...E-4 FIGURE E.1 –...
  • Page 36 FIGURE E.2 – ENGINE, EXCITATION, ROTOR AND STATOR ENGINE MECHANICAL ROTATION MAGNETO IDLER SOLENOID IDLER P.C. BOARD ENGINE, EXCITATION, ROTOR AND STATOR A small voltage developed by the engine magneto is rectified on the idler P.C. board and fed to the rotating field coil in the rotor via a brush and slip ring configu- ration.
  • Page 37 FIGURE E.3 – ROTOR FIELD FEEDBACK, AUXILIARY POWER AND ENGINE IDLE CONTROL ENGINE MECHANICAL ROTATION MAGNETO IDLER SOLENOID IDLER P.C. BOARD ROTOR FIELD FEEDBACK, AUXILIARY POWER AND ENGINE IDLE CONTROL The AC voltage developed in the field winding is fed to the full wave rectifier bridge.
  • Page 38 FIGURE E.4 – WELD WINDING, OUTPUT RECTIFIER AND CHOKE ENGINE MECHANICAL ROTATION MAGNETO IDLER SOLENOID IDLER P.C. BOARD WELD WINDING, OUTPUT RECTIFIER AND CHOKE The AC voltage developed in the stator weld winding is delivered through the current transformer to the out- put rectifier bridge, where the AC voltage is rectified to a DC voltage.
  • Page 39 Section F-1 TROUBLE SHOOTING & REPAIR SECTION Troubleshooting & Repair Section ...Section F How to Use Troubleshooting Guide ...F-2 PC Board Troubleshooting Procedures ...F-3 Troubleshooting Guide ...F4 - F-12 Test Procedures Rotor Voltage Test ...F-13 Rotor Resistance Test ...F-15 Output Rectifier Bridge Test...F-18 Main Stator Test ...F-20 Rotor “Flashing”...

  • Page 40: Troubleshooting And Repair

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only 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 41: Pc Board Troubleshooting Procedures

    • If the PC Board uses protective shorting jumpers, don’t remove them until installation is complete. • 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 proper failure analysis.

  • Page 42: Troubleshooting Guide

    Engine operates normally. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 43 Engine runs normally. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 44 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 45 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353. detailed in the beginning of this manual.
  • Page 46 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 47 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353. detailed in the beginning of this manual.
  • Page 48 “HIGH” position. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 49 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 50 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

  • Page 51: Rotor Voltage Test

    F-13 TROUBLESHOOTING & REPAIR Service and repair should be performed by only 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 52 F-14 TROUBLESHOOTING & REPAIR ROTOR VOLTAGE TEST (continued) FIGURE F.1 - LOCATION OF LEAD 202 FOR ROTOR VOLTAGE TEST LEAD 202 CONNECTION (TOP TERMINAL, CASE FRONT IN PLACE TEST PROCEDURE 1. With the 5/16” nut driver, remove the 8 sheet metal screws that hold the top cover to the control box.

  • Page 53: Rotor Resistance Test

    TROUBLESHOOTING & REPAIR ROTOR RESISTANCE TEST Service and repair should be performed by only 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 54 F-16 TROUBLESHOOTING & REPAIR ROTOR RESISTANCE TEST (continued) FIGURE F.2 – LOCATION OF ROTOR SLIP RINGS - BRUSH HOLDER ASSEMBLY REMOVED SLIP RINGS TEST PROCEDURE 1. Conduct the test with the gasoline engine OFF. 2. Remove the spark plug wire to prevent accidental engine kickback or starting.
  • Page 55 F-17 TROUBLESHOOTING & REPAIR ROTOR RESISTANCE TEST (continued) FIGURE F.3 – BRUSHES RETAINED WITH CABLE TIE CABLE BRUSHES 9. Reinstall the brush holder assembly after the test. Depress the spring-loaded 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.

  • Page 56: Output Rectifier Bridge Test

    TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST Service and repair should be performed by only 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 57 F-19 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE TEST (continued) FIGURE F.4 - OUTPUT RECTIFIER BRIDGE TEST PROCEDURE 1. Conduct this test with the gasoline engine OFF. 2. Remove the spark plug wire to prevent 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 control box.

  • Page 58: Main Stator Test

    F-20 TROUBLESHOOTING & REPAIR Service and repair should be performed by only 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 59 F-21 TROUBLESHOOTING & REPAIR MAIN STATOR TEST (continued) FIGURE F.5 - LOCATION OF LEADS W1 AND W2 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.
  • Page 60 F-22 TROUBLESHOOTING & REPAIR MAIN STATOR TEST (continued) FIGURE F.6 - MAIN STATOR MOLEX PLUG TEST POINTS FIGURE F.6 MAIN STATOR MOLEX PLUG TEST POINTS 6A – Black 5A – White 3A – Black 7A – Blue 15A – Yellow 9A –...

  • Page 61: Rotor "Flashing" Circuit Test

    TROUBLESHOOTING & REPAIR ROTOR “FLASHING” CIRCUIT TEST Service and repair should be performed by only 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 62 F-24 TROUBLESHOOTING & REPAIR ROTOR “FLASHING” CIRCUIT TEST (continued) FIGURE F.8 - BRUSH HOLDER LEADS 201A(-) AND 202B (+) Slip Rings TEST PROCEDURE 1. With the 5/16" nut driver, remove the 8 sheet metal screws that hold the top cover to the control box.
  • Page 63 F-25 TROUBLESHOOTING & REPAIR ROTOR “FLASHING” CIRCUIT TEST (continued) FIGURE F.10 - IDLER P.C. BOARD PIN ASSIGNMENTS CURRENT TRANSFORMER WARNING 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.

  • Page 64: Engine Throttle Adjustment Test

    TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed by only 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 65 F-27 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.11 - BLOWER PADDLE MARKED FOR STROBE-TACH METHOD TEST PROCEDURE This test can be conducted by any of three methods. Strobe-tach Method: 1. Remove the spark plug wire to prevent accidental kickback or starting.
  • Page 66 F-28 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.12 - IDLE SPEED ADJUSTMENT SCREW LOCATIONS HIGH IDLE INCREASE SPEED SCREW 5. ADJUST HIGH IDLE: With the Idler Switch set on HIGH, the tach should read between 3700 and 3800 RPM. a.
  • Page 67 F-29 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.13 - LOW IDLE ADJUSTMENT NUT ON IDLER SOLENOID Housing 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.
  • Page 68 F-30 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) 4. ADJUST LOW IDLE: Using a piece of dowel rod or a long screw driver, push the governor arm back until the Carburetor Throttle Lever rests against the Low Idle Speed screw. See Figure F.12. You can also push the arm back with your hand, but this is not recommended because you could be burned by the hot muffler.

  • Page 69: Normal Open Circuit Weld Voltage Waveform

    F-31 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 5 ms 50 volts This is the typical output voltage gen- erated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.

  • Page 70: Normal Open Circuit Voltage Waveform (115 Vac Supply

    F-32 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY) HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 1 Period = 16.2 ms @ 3700 rpm 5 ms 50 volts This is the typical AC output voltage generated from a properly operating machine.
  • Page 71 F-33 TROUBLESHOOTING & REPAIR TYPICAL WELD OUTPUT WAVEFORM MACHINE LOADED TO 125 AMPS AT 25 VAC MACHINE LOADED 5 ms 20 volts This is the typical 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.

  • Page 72: Abnormal Open Circuit Weld Voltage Waveform

    F-34 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM 5 ms 50 volts This is not the typical DC output voltage waveform. Note the “gap” in the waveform. One output diode was disconnected to simulate an “open”...

  • Page 73: Brush Removal And Replacement

    TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT Service and repair should be performed by only 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 74 F-36 TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT (continued) FIGURE F.14 - BRUSHES RETAINED WITH CABLE TIE CABLE 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.
  • Page 75 F-37 TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT (continued) (continued) PROCEDURE 8. To reinstall the brush holder assembly, depress the spring-loaded brushes into the holder and slip a suitable non-metal- lic, fairly stiff retainer through the slots at the top and bottom of the holder. A cable tie works well;...

  • Page 76: Rheostat Removal And Replacement

    TROUBLESHOOTING & REPAIR RHEOSTAT REMOVAL AND REPLACEMENT Service and repair should be performed by only 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 77 F-39 TROUBLESHOOTING & REPAIR RHEOSTAT REMOVAL AND REPLACEMENT (continued) See Figure F.15 for steps 3 - 9. 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.

  • Page 78: Field Capacitor Removal And Replacement

    TROUBLESHOOTING & REPAIR FIELD CAPACITOR REMOVAL AND REPLACEMENT Service and repair should be performed by only 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 79 F-41 TROUBLESHOOTING & REPAIR FIELD CAPACITOR REMOVAL AND REPLACEMENT (continued) FIGURE F.16 - DISCHARGING THE FIELD CAPACITOR Attachment for 202B Cable Tie 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.

  • Page 80: Field Diode Bridge Removal And Replacement

    TROUBLESHOOTING & REPAIR FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT Service and repair should be performed by only 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 81 F-43 TROUBLESHOOTING & REPAIR FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.17 - DISCHARGING THE FIELD CAPACITOR Attachment for 202B Cable Tie 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.
  • Page 82 F-44 TROUBLESHOOTING & REPAIR FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.18 - FIELD DIODE BRIDGE LOCATION 7A (Blue) 201 (Black) 201C (Black) – 5. The field diode bridge is mounted to the sheet metal just above the capacitor. See Figure F.18.
  • Page 83 TROUBLESHOOTING & REPAIR IDLER PRINTED CIRCUIT BOARD REMOVAL Service and repair should be performed by only 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 84: Idler Printed Circuit Board Removal And Replacement

    F-46 TROUBLESHOOTING & REPAIR IDLER PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.19 - IDLER P.C. CIRCUIT BOARD MOUNTING SCREWS PROCEDURE Before starting the following procedure, refer to the topic "PC Board Troubleshooting Procedures" at the beginning of this section. 1.

  • Page 85: Output Rectifier Bridge Removal And Replacement

    TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL Service and repair should be performed by only 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 86 F-48 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.20 - OUTPUT RECTIFIER CONNECTIONS PROCEDURE 1. Remove the engine spark plug wire to pre- vent accidental kickback or starting. 2. With the 5/16" nut driver, remove the 8 sheet metal screws from the case top.
  • Page 87 F-49 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER BRIDGE REMOVAL 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" wrench, install the "N" negative lead and the #204 lead to the negative heat sink.

  • Page 88: Output Choke Removal And Replacement

    TROUBLESHOOTING & REPAIR OUTPUT CHOKE REMOVAL AND REPLACEMENT Service and repair should be performed by only 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 89 F-51 TROUBLESHOOTING & REPAIR OUTPUT CHOKE REMOVAL AND REPLACEMENT (continued) FIGURE F.21 - OUTPUT CHOKE MOUNTING DETAILS PROCEDURE 1. Remove the engine spark plug wire to pre- vent accidental kickback or starting. 2. With the 5/16" nut driver, remove the 8 sheet metal screws from the case top.
  • Page 90 F-52 TROUBLESHOOTING & REPAIR OUTPUT CHOKE REMOVAL AND REPLACEMENT (continued) 14. Reassembly: Install the output choke assembly by setting it down into position. Fit the idler solenoid plunger into the sole- noid housing. 15. Assemble the quick connect splice that connects lead #14 to lead #14A.

  • Page 91: Stator/Rotor Removal And Replacement (Kit S20925

    TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT Service and repair should be performed by only 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 92 F-54 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT(continued) STATOR REMOVAL PROCEDURE 1. Remove the engine spark plug wire to pre- vent accidental kickback or starting. 2. Perform the Output Rectifier Bridge Removal procedure. 3. Perform the Output Choke Removal proce- dure.
  • Page 93 F-55 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.22 - STATOR END BRACKET SUPPORT AND THRU-BOLTS THRU- BOLTS SUPPORT 13. Slide a short length of 2 X 4 under the engine to support it when the stator is removed.
  • Page 94 Pull out the thru-bolt. 3. Install the long thru-bolt supplied with Lincoln Electric Rotor Removal Kit S20925. The slot head must face out. Screw in the bolt with the slot head screw driver until the bolt bottoms out on the engine crankshaft, about 3/4".
  • Page 95 F-57 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.24 - CHECKING ROTOR-STATOR AIR GAP ROTOR 4. Install the end bracket. install the two top thru-bolts loosely to hold the end bracket for the next step. 5. Install the end bracket support. 6.
  • Page 96 F-58 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) 18. Install the output choke. topic "OUTPUT CHOKE REMOVAL 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.

  • Page 97: Retest After Repair

    Output values of each receptacle can vary within the range shown but must be within 2 volts of each other. RETEST AFTER REPAIR ENGINE OUTPUT No Load RPM 3800 3700 WELDER/GENERATOR OUTPUT Field Amps Open Circuit Volts 4.0 - 6.4 75 - 82 –...
  • Page 98 NOTES WELDANPOWER 125...
  • Page 99 Section G-1 Section G-1 TABLE OF CONTENTS DIAGRAMS SECTION Diagrams Section...Section G Wiring 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 WELDANPOWER 125...
  • Page 100 DIAGRAMS WIRING DIAGRAM — (CODE 10158 & 10160) B L K R E D W H I T E NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. WELDANPOWER 125...
  • Page 101 IDLER PC BOARD (M17578) SCHEMATIC NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. This Printed Circuit Board Schematic is provided for reference only. It may not be totally applicable to your machine’s specific PC board version. This dia- gram is intended to provide general information regarding PC board function.
  • Page 102 DIAGRAMS DIMENSION PRINT — WELDANPOWER 125 WELDANPOWER 125...
  • Page 103 NOTES WELDANPOWER 125...
  • Page 104 M17578 IDLER PC BOARD M17578-1 NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discour- ages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 105 MOV-130VRMS,38J,14MM IC-COMPARATOR,QUAD,2901N NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discour- ages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 106 NOTES WELDANPOWER 125...

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