Lincoln Electric SVM 113-A User Manual

WELDANPOWER 125

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 READ­ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,

most importantly, think before
you act and be careful.

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SVM 113-A

January, 1996

TM

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World’s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

SERVICE MANUAL

Sales and Service through subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. [phone]

i i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American W elding Society, P .O. Box 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.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn 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.

____________________________________________________

1.c. Do not add the fuel near an open flame weld-

ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers

and devices in position and in good
repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.

____________________________________________________

1.e. 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
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle con­trol rods while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

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1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii ii

SAFETY

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.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS 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 and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

5.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

vapors

to

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5.e. Also see item 1.b.

Mar ‘95

iii iii

SAFETY

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.

materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn 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. National
Electrical Code and the manufacturer’s recommendations.

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Mar ‘95

iv iv

SAFETY

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. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher met­allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonc­tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à soud­er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSAStandard
W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons 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

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PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

v v

RETURN TO MAIN INDEX

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page

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

Controls and Settings.................................................................................................................B-4

Engine Operation........................................................................................................................B-6

Accessories...........................................................................................................................Section C

Maintenance .........................................................................................................................Section D

Safety Precautions............................................................................................................................D-2

Routine and Periodic Maintenance ...................................................................................................D-2

General Assembly Exploded View....................................................................................................D-6

Theory of Operation .............................................................................................................Section E

Troubleshooting and Repair .................................................................................................Section F

Electrical Diagrams..............................................................................................................Section G

Parts Manual.................................................................................................................................P-256

WELDANPOWER 125

Section A-1 Section A-1

TABLE OF CONTENTS

- 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

Plugs and Hand-Held Equipment .......................................................................................A-6

Auxiliary Power Receptacles ................................................................................................A-6

Premises Wiring....................................................................................................................A-7

Circuit Breakers ....................................................................................................................A-7

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WELDANPOWER 125

A-2 A-2

INSTALLATION

TECHNICAL SPECIFICATIONS - WELDANPOWER 125

INPUT - GASOLINE ENGINE

Manufacturer Description Speed Displacement Ignition Capacities

Briggs & 1 cyl., 3400 RPM 18.06 cu. in. Manual, Fuel: 1.6 gal. (6.0 l)
Stratton 4 cycle Full Load (296 cc) Recoil

Vanguard

®

air-cooled 3750 RPM start; Manual Oil: 1.25 qt. (1.2 l)

gasoline High Idle choke

9 HP @ 2400 RPM

3600 RPM Low Idle

RATED OUTPUT - WELDER

Duty Cycle Amps Volts at Rated Amperes

30% Duty Cycle 125 Amps DC 25 VDC
60% Duty Cycle 100 Amps DC 25 VDC

OUTPUT - WELDER AND GENERATOR

Welding Ranges Welder Open Circuit Voltage AC Auxiliary Power

50 - 125 Amps 80 VDC Max. 4500 Continuous Watts

(3500 Watts CSA)

PHYSICAL DIMENSIONS

Height Width Depth Weight

21.13 in. 20 in. 30 in. 190 lb.
530 mm 508 mm 762 mm 86.4 kg

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WELDANPOWER 125

A-3 A-3

INSTALLATION

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; and parts
lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live
parts or electrodes with your
skin or wet clothing.

• Insulate yourself from the work
and ground.

• Always wear dry insulating
gloves.

LOCATION AND VENTILATION

Whenever you use the WELDANPOWER 125, be sure
that clean cooling air can flow through the machine’s
gasoline engine and the generator. Avoid dusty, dirty
areas. Also, keep the machine away from heat
sources. Do not place the back end of the generator
anywhere near hot engine exhaust from another
machine. And of course, make sure that engine
exhaust is ventilated to an open, outside area.

The WELDANPOWER 125 may be used outdoors. Do
not set the machine in puddles or otherwise submerge
it in water. Such practices pose safety hazards and
cause improper operation and corrosion of parts.

Always operate the WELDANPOWER 125 with the
case roof on and all machine components completely
assembled. This will protect you from the dangers of
moving parts, hot metal surfaces, and live electrical
devices.

STORING

1. Store the machine in a cool, dry place when it’s
not in use. Protect it from dust and dirt. Keep it
where it can’t be accidentally damaged from con­struction activities, moving vehicles, and other
hazards.

ENGINE EXHAUST can kill.

• Use in open, well ventilated
areas or vent exhaust to the out­side.

• Do not stack anything on or near
the engine.

MOVING PARTS can injure.

• Do not operate this equipment
with any of its doors open or
guards off.

• Stop the engine before servicing
it.

• Keep away from moving parts.

Only qualified personnel should install, use, or ser­vice this equipment.

2. If you will be storing the machine for over 30 days,
you should drain the fuel to protect fuel system
and carburetor parts from gum deposits. Empty
all fuel from the tank and run the engine until it
stops from lack of fuel.

3. You can store the machine for up to 24 months if
you use Briggs & Stratton Gasoline Additive, Part
No. 5041 (available from any Authorized Briggs &
Stratton Service Center), in the fuel system. Mix
the additive with the fuel in the tank and run the
engine for a short time to circulate the additive
through the carburetor.

4. While the engine is still warm, drain the oil and refill
with fresh 10W30 oil.

5. Remove the spark plug and pour approximately
1/2 ounce (15 ml) of engine oil into the cylinder.
Replace the spark plug and crank the engine slow­ly to distribute the oil.

6. Clean any dirt and debris from the cylinder and
cylinder head fins and housing, rotating screen,
and muffler areas.

7. Store in a clean, dry area.

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WELDANPOWER 125

A-4 A-4

INSTALLATION

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. It can operate at an angle,
but this should never be more than 15 degrees in any
direction. If you do operate it at a slight angle, be sure
to check the oil regularly and keep the oil level full.
Also, fuel capacity will be a little less at an angle.

LIFTING

The WELDANPOWER 125 should be lifted by two peo­ple. (It weighs 190 lbs/86.4 kg.) Its welded tube roll
cage is designed to make lifting easy.

PRE-OPERATION ENGINE SERVICE

Read and understand the information about the gaso­line engine in the Operation and Maintenance sec­tions of this manual before you operate the
WELDANPOWER 125.

WARNING

• Keep hands away from the engine muffler or HOT
engine parts.

OIL

The WELDANPOWER 125 is shipped with
the engine filled with SAE 10W-30 oil.

CHECK THE OIL LEVEL BEFORE YOU START THE
ENGINE. This is an added precaution. Do not screw

in the dipstick when checking the oil. If it is not full,
add enough oil to fill it. DO NOT OVERFILL. Be sure
the fill plug is tight.

For more oil fill and service information, see the
Maintenance section of this manual.

FUEL

Fill the fuel tank with clean, fresh, regular
grade lead-free gasoline. DO NOT MIX OIL

WITH THE GASOLINE.

The WELDANPOWER 125 has a plastic, 1.6
gallon (6.0 liter) fuel tank mounted on the engine. See
the Operation and Maintenance sections of this
manual for more details about fuel.

SPARK ARRESTER

Gasoline engine mufflers may emit sparks when the
engine is running. Some federal, state, or local laws
require spark arresters in locations where unarrested
sparks could present a fire hazard.

Standard mufflers and deflectors (like the ones includ­ed with the WELDANPOWER 125) do not act as spark
arresters. When local laws require it, a spark arrester
must be installed on the machine and properly main­tained. Consult Briggs & Stratton for proper engine
spark arrester.

• Stop the engine when fueling.

• Do not smoke when fueling.

• Remove the fuel cap slowly to release pressure.

• Do not overfill the fuel tank.

• Wipe up spilled fuel and allow the fumes to clear
before starting the engine.

• Keep sparks and flame away from the fuel tank.

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WELDANPOWER 125

A-5 A-5

INSTALLATION

FIGURE A.1 - WELDANPOWER 125 OUTPUT CONNECTIONS

1

6

5

2

1. CURRENT CONTROL DIAL

2. WELD OUTPUT TERMINALS (2)

3. GROUND STUD

ELECTRICAL OUTPUT
CONNECTIONS

See Figure A.1 for the location of the current control
dial, weld output terminals, ground stud, circuit break­ers, 230 and 115 volt receptacles.

WELDING CABLE CONNECTIONS

Cable Size and Length

Be sure to use welding cables that are large enough.
The correct size and length becomes especially impor­tant when you are welding at a distance from the
welder.

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.

3

4. CIRCUIT BREAKERS (2) - 20 AMP (15 AMP CSA)

5. RECEPTACLE - 230 VOLT, 20 AMP (15 AMP CSA)

6. DUPLEX RECEPTACLE - 115 VOLT, 20 AMP (15 AMP CSA)

TABLE A.1

RECOMMENDED WELDING CABLE

SIZE AND LENGTH

TOTAL COMBINED LENGTH OF ELECTRODE AND

WORK CABLES

Cable Length 30% Duty Cycle

0-50 feet (0-15 meters) 6 AWG
50-100 feet (15-30 meters) 5 AWG
100-150 feet (30-46 meters) 3 AWG
150-200 feet (46-61 meters) 2 AWG
200-250 feet (61-76 meters) 1 AWG

4

Cable Size for

125 amp/

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WELDANPOWER 125

A-6 A-6

INSTALLATION

Cable Installation

Install the welding cables to your WELDANPOWER
125 as follows. See Figure A.1 for the location of
parts.

1. The gasoline engine must be OFF to install weld-

ing cables.

2. Remove the 1/2 - 13 flanged nuts from the output

terminals.

3. Connect the electrode holder and work cables to

the weld output terminals. Normally, the electrode
cable is connected to the positive (+) output termi­nal.

4. Tighten the flanged nuts securely.

5. Be certain that the metal piece you are welding

(the “work”) is securely connected to the work
clamp and cable.

6. Check and tighten the connections periodically.

CAUTION

• Loose connections will cause the output terminals to
overheat. The terminals may eventually melt.

• Do not cross the welding cables at the output termi­nal connection. Keep the cables isolated and sepa­rate from one another.

Lincoln Electric offers a welding accessory kit with the
properly specified welding cables. See the
Accessories section of this manual for more informa­tion.

WARNING

Do not ground the machine to a pipe that carries
explosive or combustible material.

When the WELDANPOWER 125 is
mounted on a truck or a trailer, the
machine generator ground stud MUST
be securely connected to the metal
frame of the vehicle. See Figure A.1.
The ground stud is marked with the symbol.

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 insu­lation system with a two-blade plug. Lincoln offers an
accessory plug kit that has the right type of plugs. See
the Accessories section of this manual for details.

If you need ground fault protection for hand-held
equipment, in-line ground fault current interrupter
(GFCI) cord sets that meet UL and OSHA requirements
are also available as an option. See the Accessories
section of this manual for details.

AUXILIARY POWER RECEPTACLES

The control panel of the WELDANPOWER 125 features
two auxiliary power receptacles:

• A 20 amp, 115 volt duplex (double outlet) receptacle
(15 amp CSA).

• A 20 amp 230 volt simplex (single outlet) receptacle
(15 amp CSA).

an earth ground. However, for best protection against
electrical shock, connect a heavy gauge wire (#8 AWG
or larger) from the ground stud located on the bottom
center of the output panel (see Figure A.1) to a suitable
earth ground such as a metal pipe driven into the
ground.

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MACHINE GROUNDING

Because the WELDANPOWER 125 cre­ates its own power from its gasoline­engine driven generator, you do not
need to connect the machine frame to

WELDANPOWER 125

See Figure A.1.

CAUTION

The 20 amp, 115 volt duplex receptacle is “split
phase.” Damage will result if you attempt to connect
both sides of this receptacle in parallel to a load.

Through these receptacles the machine can supply up
to 4,500 watts of single-phase AC power (3500 watts
CSA). The machine output voltages meet UL stan­dards and fall within ± 10% of the rated voltage. The
output frequency falls within ± 3% of rated frequency
(60 Hz).

A-7 A-7

INSTALLATION

PREMISES WIRING

The WELDANPOWER 125 three-wire, grounded neu­tral generator allows it to be connected to premises
wiring. However , the wiring pr ocedure 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” to the premises or only connected tem­porarily.

WARNING

Only a licensed, certified, trained electrician should
install the machine to a premises or residential electri­cal system. Be certain that:

• The premises is isolated and no feedbacking into
the utility system can occur. Certain state and local
laws require the premises to be isolated before the
generator is linked to the premises. Check your
state and local requirements.

• A double pole, double throw transfer switch in con­junction with the properly rated double throw circuit
breaker is connected between the generator power
and the utility meter.

CIRCUIT BREAKERS

The WELDANPOWER 125 has its own
20 amp circuit breakers for overload
protection (15 amp CSA). When the
machine is operated in high temperature environ­ments, the breakers may tend to trip at lower loads
than normally.

CAUTION

Never bypass the circuit breakers. Without overload
protection, the WELDANPOWER 125 could overheat
and/or cause damage to the equipment being used.

The WELDANPOWER 125 does not have a combined
115/230 volt twist-lock receptacle and cannot be con­nected to a premises as described in other Lincoln lit­erature.

Remember that the WELDANPOWER 125 is intended
only for backup, intermittent use. It cannot withstand
long-term use without proper maintenance. See the
Maintenance section of this manual for more informa­tion.

Certain electrical devices cannot be powered by the
WELDANPOWER 125. Refer to Table A.2 for these
devices.

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WELDANPOWER 125

A-8 A-8

INSTALLATION

CAUTION

Certain Electrical devices cannot be powered by the WELDANPOWER 125. See Table A.2.

TABLE A.2

ELECTRICAL DEVICE USE WITH THE WELDANPOWER 125.

Type Common Electrical Devices Possible Concerns

Resistive Heaters, toasters, incandescent NONE

light bulbs, electric range, hot
pan, skillet, coffee maker.

Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage

appliances with electrical control. regulation can cause the capac-

itative elements to fail. Surge
protection, transient protection,
and additional loading is recom­mended for 100% fail-safe
operation. DO NOT RUN

THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE TYPE
LOADS.

Inductive Single-phase induction motors, These devices require large

drills, well pumps, grinders, small current inrush for starting. (See
refrigerators, weed and hedge Table B.3, GENERATOR POWER
trimmers. APPLICATIONS, in the

Operation section of this manu­al for required starting
wattages.) Some synchronous
motors may be frequency sensi­tive to attain maximum output
torque, but they SHOULD BE
SAFE from any frequency
induced failures.

Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-

complicated electrical equipment. er along with transient and

surge protection is required, and
liabilities still exist. DO NOT

USE THESE DEVICES WITH A
WELDANPOWER 125.

The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected
to the WELDANPOWER 125.

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WELDANPOWER 125

Section B-1 Section B-1

TABLE OF CONTENTS

- OPERATION SECTION -

Operation...............................................................................................................................Section B

Safety Instructions......................................................................................................................B-2

General Description....................................................................................................................B-2

Recommended Applications ......................................................................................................B-3

Welder .................................................................................................................................B-3

Generator .............................................................................................................................B-3

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

Welding Operation......................................................................................................................B-8

Auxiliary Power Operation........................................................................................................B-11

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WELDANPOWER 125

B-2 B-2

OPERATION

OPERATING INSTRUCTIONS

Read and understand this entire section before oper­ating your WELDANPOWER 125.

SAFETY INSTRUCTIONS

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; and parts
lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrodes with your skin or wet cloth­ing.

• Insulate yourself from the work and
ground.

WARNING

ARC RAYS can burn.

• Wear eye, ear, and body protection.

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or
vent exhaust to the outside.

• Do not stack anything on or near the
engine.

MOVING PARTS can injure.

• Do not operate this equipment with
any of its doors open or guards off.

• Stop the engine before servicing it.

• Keep away from moving parts.

• Always wear dry insulating gloves.

FUMES AND GASES can be dan­gerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove
fumes from breathing zone.

WELDING SPARKS can cause
fire or explosion.

• Keep flammable material away.

• Do not weld on containers that have held
combustibles.

Only qualified personnel should install, use, or ser­vice this equipment.

GENERAL DESCRIPTION

The WELDANPOWER 125 is a low-cost welder/gener­ator designed for home use and other non-commercial
applications. As a welder it provides 125 amps of con­stant DC current for welding with DC stick electrodes
and for DC TIG welding. A single dial provides contin­uous adjustment of welding output from 50 to 125
amps. As a generator it can supply up to 4500 watts
of 115/230 volt, single-phase AC power. The machine
is lightweight, portable, and can be lifted easily by two
people.

A Briggs & Stratton 9 HP standard Vanguard®air­cooled, gasoline engine powers the welder/generator.

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WELDANPOWER 125

B-3 B-3

OPERATION

RECOMMENDED APPLICATIONS

WELDER

The WELDANPOWER 125 provides excellent constant
current DC welding output for stick (SMAW) welding
and DC TIG welding using the “scratch” starting tech­nique. THE K903 TIG Module can be added as an
option to provide high frequency starting. For more
details on using the machine as a welder, see WELD­ING OPERATION in the Operation section of this
manual.

GENERATOR

The WELDANPOWER 125 gives smooth AC generator
output for medium use, non-commercial demands.
For more details on operating the generator, see GEN­ERATOR OPERATION in the Operation section of this
manual.

OPERATIONAL FEATURES AND
CONTROLS

The WELDANPOWER 125 was designed for simplicity .
Therefore, it has very few operating controls. A single
dial on the control panel lets you select either welder
or generator use. For welding, the same dial selects
continuous current output over the machine’s 50 to
125 amp range.

The 9 HP Briggs & Stratton gasoline engine controls
include a recoil starter, choke, throttle control, and
stop switch. See ENGINE OPERATION in the
Operation section of this manual for details about
starting, stopping, and breaking in the gasoline
engine.

DESIGN FEATURES AND
ADVANTAGES

• DC Stick welding (SMAW) process capability with
output range from 50 - 125 amps.

• Single-dial current output selection.

• Work and Electrode welding cable mounting termi­nals.

• 4500 watts of continuous 115/230 volt, single­phase AC auxiliary power (3500 watts CSA).

• Separate ground stud for safe connection of case to
earth ground. Single 20 amp, 230 volt generator
receptacle.

• Duplex 20 amp, 115 volt generator receptacle.

• Integrated generator output overload protection
through two 20 amp circuit breakers.

• Welded-tube, full roll cage frame protects engine
and generator/welder.

• Lightweight, portable design.

• Briggs & Stratton 9 HP Vanguard®overhead valve,
air-cooled gasoline engine.

• Rubber mounting isolates engine and generator
from frame to prevent machine “walking” during
use.

• Hour meter standard.

• Automatic shutdown for low oil condition.

WELDING CAPABILITY

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 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. The WELDANPOWER 125 can, therefore,
weld with all 3/32 and most 1/8 inch diameter Lincoln
DC electrodes as well as do DC TIG welding.

LIMITATIONS

• The WELDANPOWER 125 is not recommended for
any processes besides those that are normally per­formed using stick welding (SMAW) procedures or
TIG welding.

• The WELDANPOWER 125 is not recommended for
pipe thawing.

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• During welding, generator power is limited to 100
watts, and output voltages can drop from 120 to 80
volts and 240 to 160 volts. Therefore, DO NOT
OPERATE ANY SENSITIVE ELECTRICAL EQUIP­MENT WHILE YOU ARE WELDING.

WELDANPOWER 125

B-4 B-4

OPERATION

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

9

10

2

3

4

1. CURRENT CONTROL DIAL

2. ELECTRODE SELECTION GUIDE

3. WELD POSITIVE OUTPUT TERMINAL WITH 1/2 - 13 FLANGE NUT

4. WELD NEGATIVE OUTPUT TERMINAL WITH 1/2 - 13 FLANGE NUT

5. GROUND STUD

1

8

7

5

6. 20 AMP CIRCUIT BREAKERS (2) (15 AMP CSA)

7. 20 AMP, 230 VOLT RECEPTACLE (15 AMP CSA)

8. 20 AMP, 115 VOLT DUPLEX RECEPTACLE (15 AMP CSA)

9. HOUR METER

10. IDLER CONTROL SWITCH

6

WELDER/GENERATOR CONTROLS

See Figure B.1 for the location of the following fea­tures:

1. CURRENT CONTROL DIAL: Adjusts continuous
current output. The amperages on the dial corre­spond to the average amperages needed for spe­cific Lincoln welder rods.

2. ELECTRODE SELECTION GUIDE: Provides rec­ommended electrode type, size, and welder out­put setting based on the thickness of the work.

3. WELD POSITIVE OUTPUT TERMINAL WITH 1/2 ­13 FLANGE NUT: Provides the connection point
for either the electrode holder or the work cable.
(For DC+ welding the electrode holder should be
connected to the Weld Positive Output Terminal
and the work cable to the Weld Negative Output

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Terminal. For DC– welding the electrode holder
should be connected to the Weld Negative Output
Terminal and the work cable to the Weld Positive
Output Terminal.)

4. WELD NEGATIVE OUTPUT TERMINAL WITH 1/2 ­13 FLANGE NUT: Provides the connection point
for either the electrode holder or the work cable.
(For DC+ welding the electrode holder should be
connected to the Weld Positive Output Terminal
and the work cable to the Weld Negative Output
Terminal. For DC– welding the electrode holder
should be connected to the Weld Negative Output
Terminal and the work cable to the Weld Positive
Output Terminal.

WELDANPOWER 125

B-5 B-5

OPERATION

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 sepa­rate overload current protection for the 115 volt
and 230 volt receptacles.

7. 20 AMP, 230 VOLT RECEPTACLE: Connection
point for supplying 230 volt power to operate one
electrical device.

FIGURE B.2 – GASOLINE ENGINE CONTROLS

2

9

5

4

8

12

8. 20 AMP, 115 VOLT DUPLEX RECEPTACLE:
Connection point for supplying 115 volt power to
operate one or two electrical devices.

9. HOUR METER: Records the engine running time
for maintenance purposes.

10. IDLER CONTROL SWITCH: Sets idle speed to
FAST IDLE or AUTOMATIC IDLE.

3

7

11

1

1. FUEL SHUT-OFF VALVE

2. FUEL TANK AND CAP

3. MUFFLER

4. STOP SWITCH/OIL GARD®LIGHT

5. AIR CLEANER

6. IDLER CONTROL SWITCH (NOT SHOWN)

GASOLINE ENGINE CONTROLS

See Figure B.2 for the location of the following fea­tures.

1. FUEL SHUTOFF VALVE: Stops the flow of gasoline
from the fuel tank to the carburetor. Should be
closed whenever you are finished using the WEL­DANPOWER 125. Must be opened before you
start the engine.

2. FUEL TANK AND CAP: Holds 1.6 gallon (6.0 liters)
of unleaded gasoline. Contains a 50 micron fuel
filter molded at the outlet port.

NOTE: If you use any other alternate fuel tank or

supply, be sure to use a recommended in­line fuel filter.

3. MUFFLER: Reduces engine noise output. Does
not serve as a spark arrester. See SPARK
ARRESTER in the Installation section of this man­ual.

4. ROCKER STOP SWITCH/OIL GARD®LIGHT:
Stops the engine by grounding the ignition circuit.
Glows red when engine oil level is low.

7. CARBURETOR

8. RECOIL STARTER

9. THROTTLE AND CHOKE CONTROLS

10. FUEL MIXTURE ADJUSTMENT SCREW (NOT SHOWN)

11. OIL DRAIN PLUG

12. OIL FILL/DIPSTICK

5. AIR CLEANER: Filters intake air to the carburetor.
See ENGINE MAINTENANCE in the Maintenance
section of this manual for details about the specif­ic type of air cleaner to use.

6. IDLER CONTROL SWITCH: (Not
shown. See item 10, Figure B.1.)
Adjusts the running speed of the
engine. The switch has two positions,
HIGH and AUTO. In HIGH, the
engine runs continuously at high
idle. In AUTO, the idler control
works as follows:

Welding: The engine accelerates to high speed
when the electrode touches the work and strikes a
welding arc. The engine returns to low idle
approximately 12 seconds after welding stops, as
long as no auxiliary power is being drawn.

Auxiliary Power: The engine accelerates to high
speed when power is drawn at the receptacles for
lights or tools. The engine returns to low idle
approximately 12 seconds after demand for auxil­iary power stops.

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WELDANPOWER 125

B-6 B-6

OPERA TION

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 FOL­LOWING THE PROCEDURES OUTLINED BY
BRIGGS & STRATTON.

8. RECOIL STARTER: Manual, rope-type starter. The
handle position allows easy starting from either
ground level or pickup-truck level.

9. CHOKE: Provides a richer air/fuel mix­ture for cold engine starting conditions.
See the topic ENGINE OPERATION,
below, for details on setting the choke.

10. FUEL MIXTURE ADJUSTMENT SCREW (Not
shown): Adjusts the amount of fuel mixed with air
to obtain the smoothest operation under load or at
idle. The WELDANPOWER 125 is shipped with
the proper adjustment already set. DO NOT

ADJUST THE FUEL MIXTURE SCREW WITH­OUT FOLLOWING THE PROCEDURES OUT­LINED BY BRIGGS & STRATTON.

11. OIL DRAIN PLUG: Permits convenient draining of
engine oil during maintenance. Both sides of the
engine are equipped with an oil drain plug.

12. OIL FILL/DIPSTICK: Permits convenient filling of
engine oil during maintenance. Both sides of the
engine are equipped with an oil fill/dipstick.

ENGINE OPERATION

BEFORE STARTING THE ENGINE

CHECK AND FILL THE ENGINE OIL LEVEL:

1. Place the machine on a level sur­face.

2. Clean around the oil fill, then remove the dipstick.

3. Fill (if necessary) to full mark on the dipstick. Do
NOT screw in the dipstick to check.

4. Replace the dipstick and tighten securely. For
more details on checking and filling the oil, see
ENGINE MAINTENANCE in the Maintenance sec­tion of this manual.

CHECK AND FILL THE ENGINE FUEL TANK:

1. Remove the fuel tank cap.

2. Fill the tank to allow approximately 1/4
inch (5 mm) of tank space for fuel
expansion. DO NOT FILL THE TANK
TO THE POINT OF OVERFLOW.

3. Replace the fuel tank cap and tighten securely.

NOTE: The engine will operate satisfactorily on any

gasoline meant for automotive use. A mini­mum of 87 octane is recommended. DO NOT
MIX OIL WITH THE GASOLINE.

Use clean, fresh, lead-free gasoline. Leaded gasoline
may be used if lead-free is not available. However,
lead-free gasoline leaves fewer combustion deposits
and gives longer valve life. For engine protection from
fuel deposits, use Briggs & Stratton Gasoline Additive,
part number 5041. Purchase gasoline in quantities
that will be used within 30 days, to assure freshness.

DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS.
The maximum allowable high idle speed for the
WELDANPOWER 125 is 3750 RPM, no load. Do NOT
adjust the governor screw on the engine. Severe per­sonal injury and damage to the machine can result if it
is operated at speeds above the maximum rated
speed.

Read and understand all safety instructions included
in the Briggs & Stratton Owner’s Manual that is
shipped with the WELDANPOWER 125.

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WARNING

NOTE: We DO NOT recommend using gasoline that

contains alcohol, such as gasohol. However,
if gasoline with alcohol is used, it MUST NOT
contain more than 10% Ethanol and MUST be
removed from the engine during storage. DO
NOT use gasoline containing Methanol.

STARTING THE ENGINE

NOTE: Remove all loads connected to the AC power

receptacles before starting the gasoline
engine.

FOR A “COLD” ENGINE:

1. Open the fuel shutoff valve on the bottom of the
engine, below the recoil starter. Rotate the lever
1/4 turn so that it is in the vertical position and the
pointer is on “O.” See Figure B.3.

2. Move the choke control to the left. See Figure B.3.

WELDANPOWER 125

B-7 B-7

OPERA TION

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 resis­tance is felt.

FIGURE B.4

IDLER CONTROL AND STOP SWITCH

4. Pull the cord rapidly.

FOR BEST ENGINE STARTING:

• Do not adjust air or fuel mixtures without following
the procedures in the Briggs & Stratton Owner’s

Manual.

• Always use fresh gasoline and be sure the filter is
clean and properly maintained.

• If you use an alternate fuel tank or supply , be sur e to
install an in-line fuel filter.

• Do not pull the recoil starter with the choke in the
left position more than one time. Repeated pulls on
a choked engine will flood the carburetor.

• If you don’t feel resistance when you pull the recoil
cord, gently hit the starter housing and/or pull the
cord out to its fully extended position and wiggle it
rapidly. Repeat this if necessary until the clutch
engages the shaft and you feel resistance when you
pull the cord.

• If the engine will not start, see the Troubleshooting
section of this manual.

STOPPING THE ENGINE

Auto

Stop SwitchIdler Control Switch

6. Pull the starter cord rapidly.

7. If the engine does not start, open the choke slight­ly (move lever right) and pull the starter cord rapid­ly again.

When the engine starts, immediately open the choke
to the right-most position. The engine will go to idle
speed after about 12 seconds.

FOR A “HOT” ENGINE:

1. Open the fuel shutoff valve on the bottom of the
engine.

1. Remove all welding and generator power loads
and let the engine cool by running it for several
minutes.

2. Stop the engine by placing the rocker run/stop
switch in the stop position.

3. Close the fuel shutoff valve at the bottom of the
engine, below the recoil starter.

WARNING

Close the fuel valve when the machine is transported
to prevent fuel leakage from the carburetor. Drain the
tank before transporting the machine in a vehicle.

For long periods of storage, turn off the fuel shutoff
valve (horizontal upward position) and let the engine
run until there is no more fuel in the line. Use a fuel
additive such as Sta-Bil to minimize fuel gum deposits.

2. Place the choke lever in the right-most, position.
Closing the choke of a hot engine will flood the
carburetor and prevent starting.

3. Pull slightly on the recoil starter handle until resis­tance is felt.

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WELDANPOWER 125

B-8 B-8

OPERATION

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 break-in. Change the
oil after the first 5 hours of operation. For more details,
see the Maintenance section of this manual.

LOW OIL SENSING

This engine has a built-in sensor that responds to low
oil level (not pressure). When activated, the “Oil Gard”
system will shut the engine down. The engine will not
restart until sufficient oil is added. Check oil level fre­quently and add oil as required to the full mark on the
dipstick. DO NOT OVERFILL.

TABLE B.1

TYPICAL FUEL CONSUMPTION

Briggs & Stratton
9 H.P. Vanguard

No Load. 0.15 Gallons/Hour
2300 R.P.M. (.57 Liters/Hour)

No Load 0.33 Gallons/Hour
3750 R.P.M. (1.25 Liters/Hour)

WELDING OPERATION

GENERAL INFORMATION

WARNING

Do not touch electrically live parts or elec­trodes with your skin or wet clothing.

Do not breathe welding fumes or gases.
Use ventilation or exhaust to remove weld-

ing fumes from the breathing area.

Keep flammable material away.
Wear eye, ear, and body protection.

Moving parts can injure.

• Do not operate this equipment with
any of its doors open or guards off.

• Stop the engine before servicing it.

• Keep away from moving parts.
Only qualified personnel should install, use, or service

this equipment.

DC CC Weld Output 0.63 Gallons/Hour
100 Amps, 25 Volts (2.4 Liters/Hour)

DC CC Weld Output 0.76 Gallons/Hour
125 Amps, 25 Volts (2.9 Liters/Hour)

Auxiliary Power 0.76 Gallons/Hour
4500 Watts (2.9 Liters/Hour)

CAUTION

During break-in, subject the WELDANPOWER 125 to
only moderate loads. Avoid long periods running at
idle. Before stopping the engine, remove all loads and
allow the engine to cool several minutes.

The WELDANPOWER 125 generator/welder can deliv­er 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.

You can get maximum welding output by setting the
dial to 125 AMPS. At high current settings like this,
some output may decrease as the machine is used. If
you are welding for a long time, you may need to turn
the dial slightly upward to maintain the same results.

The numbers on the dial correspond to the average
amps needed to weld using specific Lincoln welding
rods. Table B.2, ELECTRODE SELECTION GUIDE,
gives you the recommended dial settings based on the
thickness of the work and the size and type of rod
you’re using.

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WELDANPOWER 125

B-9 B-9

OPERATION

TO USE THE WELDANPOWER 125 FOR WELD­ING:

1. Remove the flange nuts from the weld output ter­minals 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 are tight.

2. Select the appropriate electrode. See Table B.2,
Electrode Selection Guide. This same table is
also printed on the machine Output Control Panel.

3. Attach the work clamp securely to the work you
are welding.

4. Insert the electrode into the electrode holder.

5. Set the current control dial to the desired output
current.

6. Start the gasoline engine. See Engine Operation
in this section of the manual.

7. Strike an arc and begin welding.

AFTER YOU FINISH THE WELD:

1. Stop the gasoline engine. See Engine Operation
in this section of the manual.

For DC+ welding, connect the electrode cable to the
“+” output terminal and the work cable to the “-” out­put terminal. For DC - welding, reverse these con­nections.

TIG WELDING

CAUTION

Improper use of high frequency equipment may dam­age this machine. Use only the recommended equip­ment.

The WELDANPOWER 125 can be used for DC TIG
welding using the “scratch” technique.

For high frequency starting, use the K930-1 TIG
Module.

2. Allow the electrode and work to cool completely.

3. Remove the work clamp from the work.

4. Remove any remaining piece of electrode fr om the
electrode holder.

5. If you are finished using the WELDANPOWER 125
for welding, disconnect the welding cables from
the weld output terminals. Reattach the flange
nuts and leave them on the terminals.

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WELDANPOWER 125

B-10 B-10

OPERATION

TABLE B.2

ELECTRODE SELECTION GUIDE

CURRENT RANGE (AMPS)

AWS ELECTRODE

CLASSIFICATION 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 STAINWELD® 308-16 + 50-60 55-95 80-125

ENi-Cl SOFTWELD® 99NI + 50-80 80-110 -

ABW ABRASOWELD™ + - 50-125 -

1/8 AND

MATERIAL THICKNESS THINNER

NOTES:

The values listed are suggested settings. Actual setting may vary depending on individual preference and/or spe­cific application. Beginners should use STABLE ARC E7018.

For electrodes not listed, follow tables that are packed with the electrodes.
Ask for the Lincoln WELD DIRECTORY (Publication M210) for a complete listing of all Lincoln stick electrodes

available.

1/8 AND THICKER

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WELDANPOWER 125

B-11 B-11

OPERATION

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 WEL­DANPOWER 125. Refer to Table A.2, ELECTRICAL
DEVICE USE WITH THE WELDANPOWER 125, in the
INSTALLATION section of this manual.

GENERAL INFORMATION

The WELDANPOWER 125 generator is rated at 4500
continuous watts (3500 watts CSA). It provides both
115 volt and 230 volt power. You can draw up to 20
amps from either side of the 115 volt duplex recepta­cle, but no more than 37 amps from both sides at
once. Up to 18 amps can be drawn from the single
230 volt receptacle.

CAUTION

The 115 volt duplex receptacle is “split phase.”
Damage will result if you attempt to connect both
sides of this receptacle in parallel to a load.

draws. (This information is given on the load device
nameplate.) For example, a device rated 115 volts, 2
amps will need 230 watts of power (115 x 2 = 230).

You can use Table B.3, GENERATOR POWER APPLI­CATIONS, to determine the wattage requirements of
the most common types of loads you can power with
the WELDANPOWER 125. Be sure to read the notes
at the bottom of the table.

TO USE THE WELDANPOWER 125 AS AN
AUXILIARY POWER SUPPLY:

1. Start the gasoline engine. See Engine Operation
in this section of the manual.

2. Set the current control dial on the output control
panel to “MAX.”

3. Plug the load(s) into the appropriate 115 volt or
230 volt power receptacle.

NOTE: During welding, the maximum generator out-

put for auxiliary loads is 100 watts.

NOTE: You can supply multiple loads as long as they

are isolated from each other and the total load
does not exceed 4,500 watts (3500 watts
CSA). Be sure to start the largest loads first.

Electrical loads in watts are calculated by multiplying
the voltage rating of the load by the number of amps it

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WELDANPOWER 125

B-12 B-12

OPERATION

TABLE B.3

GENERATOR POWER APPLICATIONS

Suggested Power Applications Running Watts *Start-up Watts

*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) 1,500
Electric Skillet 1,250
* Furnace Fan - 1/3 HP 1,200 3,000 - 4,800
Portable Grinder (4-1/2”) 600
Portable Grinder (7”) 2,000
Halogen Work Light 500
Hand Drill - 1/4” 500
Hand Drill - 3/8” 700
1500 Watt Heater 1,750
Hedge Trimmer 450
Light Bulb 100
Reciprocating Saw 900
Radial Arm Saw 2,600
Radio 50
*Refrigerator/Freezer (small) 600 1,500 - 2,400
Slow Cooker 200
*Submersible Pump - 1HP 1,000 2,500 - 4,000
*Sump Pump 600 1,500 - 2,400
Toaster 1,100
Weed Trimmer 500
Lincoln 100 or 125 Amp Wire Feeder/Welder 4,000

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.
Multiple loads can be used as long as the total load does not exceed 4,500 watts (3,500 watts CSA) and they are

isolated from each other. Be sure to start the largest loads first. For example, a 1 HP motor needs approximately
1,000 watts while running but may require 2,500 watts to start. Some inductive motors may require as much as
4 times running watts to start.

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WELDANPOWER 125

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

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WELDANPOWER 125

C-2 C-2

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 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.)

Accessory Set (K875) – Includes the following:

• Twenty feet (6.1 meters) of #6 AWG electrode cable

• Fifteen feet (4.6 meters) of #6 work cable

• Headshield with No. 10 filter, work clamp

• Insulated electrode holder and sample electrodes
The cables are rated at 150 amps, 40% duty cycle.
GFCI Receptacle Kit (K896-3) – Includes one UL

approved 115 volt ground fault circuit interruptor
duplex type receptacle with cover and installation
instructions. Replaces the factory installed 115 volt
receptacle. Each side of the GFCI duplex is rated 15
amps, but the maximum total current from the duplex
is limited to 20 amps.

BRIGGS AND STRATTON ACCESSORIES

The following options/accessories are available for
your WELDANPOWER 125 from your local Briggs &
Stratton Distributor.

Exhaust Deflector (REF 710281) – Directs exhaust
either right, left, or downward, away from the operator.

Undercarriage (K882-2) – A two-wheeled, hand mov­able undercarriage. Field installed.

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WELDANPOWER 125

D-1 D-1

TABLE OF CONTENTS

-MAINTENANCE-

Maintenance .........................................................................................................................Section D

Routine and Periodic Maintenance ............................................................................................D-2

Engine Maintenance.............................................................................................................D-2

Welder/Generator Maintenance...........................................................................................D-5

Major Component Locations......................................................................................................D-6

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WELDANPOWER 125

D-2 D-2

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.

• If guards are missing fr om the machine, get replace­ments from a Lincoln Distributor.

Read the Safety Precautions in the front of this manu­al and in the Briggs & Stratton Owner’ s Manual before
working on the WELDANPOWER 125.

Keep all equipment safety guards, covers, and devices
in position and in good repair. Keep your hands, hair,
clothing, and tools away from the recoil housing, fans,
and all other moving parts when starting, operating, or
repairing this machine.

OIL: Check the oil level after every 5
hours of operation or daily. BE SURE

TO MAINTAIN THE OIL LEVEL.
Change the oil the first time after 5 hours of operation.
Then, under normal operating conditions, change the
oil after every 50 hours or once a year, whichever
occurs first. If the engine is operated under heavy load
or in high ambient temperatures, change the oil every
25 hours.

Drain the oil from the drain plug located on the engine
bottom, as shown in Figure D.1. Refill through the oil
fill until the oil reaches the FULL mark on the dipstick.
See Figure D.2. Use SAE 10W-30 grade oil.

FIGURE D.1 - OIL DRAIN AND

REFILL LOCATION

ROUTINE AND PERIODIC
MAINTENANCE

ENGINE MAINTENANCE

CAUTION

To prevent the engine from accidentally starting, dis­connect the spark plug lead before servicing the
engine.

See Table D.1 for a summary of maintenance intervals
for the items listed below. Follow either the hourly or
the calendar intervals, whichever come first. More fre­quent service may be required, depending on your
specific application and operating conditions. Table
D.2 shows engine maintenance replacement parts and
numbers.

FIGURE D.2 - OIL CHECK PROCEDURE

Do not screw in

dipstick to

check oil

FUEL: At the end of each day’s use, refill
the fuel tank to minimize moisture conden­sation and dirt contamination in the fuel line.

Fill to FULL

mark on dipstick

- recheck

Tighten dipstick

firmly before

starting

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WELDANPOWER 125

D-3 D-3

MAINTANENCE

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 operat­ing conditions.

CAUTION

Do not use petroleum solvents such as kerosene to
clean the cartridge. They may cause deterioration of

the cartridge. DO NOT OIL THE CARTRIDGE OR USE
PRESSURIZED AIR TO CLEAN OR DRY THE CAR­TRIDGE.

Remove the wing nuts and cover. Carefully remove
the foam pre-cleaner from the cartridge.

To service the pre-cleaner:

1. Wash in liquid detergent and water.

2. Squeeze dry in a clean cloth.

3. Saturate in clean engine oil.

4. Squeeze in a clean, absorbent cloth to remove all

excess oil.

To service the cartridge:

Clean Rotating Screen: See Figure D.3. Clean the
rotating screen on your machine’s engine as often as
needed to remove dirt or debris that may collect on the
screen. A dirty screen can result in engine overheating
and damage.

FIGURE D.3 - CLEAN FINGER GUARD

1

1. FINGER GUARD

CLEAN COOLING SYSTEM: See Figure D.4. Clean
the internal cooling fins and surfaces to prevent over­speeding, overheating, and engine damage. Clean
every 100 operating hours or as often as necessary.

FIGURE D.4- CLEAN COOLING SYSTEM

1. Tap gently on a clean surface.

2. Replace if very dirty or wash in a non-sudsing deter-

gent and warm water solution.

3. Rinse thoroughly from the mesh side with flowing

water until the water is clear.

4. Allow to stand and air dry before reinstalling.
Carefully place the pre-cleaner back over the cartridge

and reinstall the air cleaner cover and wingnuts.
CLEAN ENGINE: Remove dirt and debris with a cloth

or a brush. Do not clean with a forceful spray of water.
Water might contaminate the fuel system.

CAUTION

Periodically clean the muffler area to remove com­bustible debris.

1

1. REMOVE CHAFF AND DIRT FROM THESE AREAS.

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WELDANPOWER 125

D-4 D-4

MAINTENANCE

CLEAN OR REPLACE SPARK PLUG: Clean or

replace the spark plug after every 100 hours of opera­tion 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. Wash the plug with a commercial solvent.
After cleaning or when installing a new spark plug, set
the terminal gap to .030 inch (.76 mm) with a feeler
gauge. See Figure D.5.

FIGURE D.5 - SET SPARK PLUG GAP

2

1

1. SPARK PLUG (RESISTOR, PART NO. 491055)

2. FEELER GAUGE (.030 INCH, 76mm)

REMOVE COMBUSTION DEPOSITS: After every
100 hours of properly, remove the engine cylinder
head. Scrape and wire brush the combustion deposits
from the cylinder, cylinder head, top of the piston, and
around the valves. Refit the gasket (replace it if dam­aged) and reassemble the cylinder head and block.
Tur n down the screws finger tight. Torque the screws
in a staggered sequence to 165 inch-pounds (19 N·m).

TABLE D.1

ENGINE MAINTENANCE SCHEDULE

Maintenance Every 8 Hours 25 Hours 50 Hours 100 Hours
Operation or Daily or Yearly or Yearly or Yearly

Check Oil Level ●
Change Oil ◆●Note 1
Clean Finger Guard ●

Note 2

Service Foam Pre-Cleaner

Service Air Cleaner Cartridge ●

Clean Cooling System ●

Clean or Replace Spark Plug ●
Clean Fuel Filter ●
Remove Combustion Deposits ●

◆ Change oil after first 5 hours, then after every 50 hours or once a year.

Note 1: Change oil every 25 hours when operating under heavy load in high ambient temperatures.
Note 2: Clean more often under dusty conditions or when airborne debris is present.

●

Note 2

Note 2

Note 2

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WELDANPOWER 125

D-5 D-5

MAINTENANCE

TABLE D.2 – ENGINE MAINTENANCE PARTS

Part Part Number

OIL FILTER NONE
SPARK PLUG (STANDARD) B&S 492167
SPARK 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)

WELDER/GENERATOR MAINTENANCE

STORAGE: Store the WELDANPOWER 125 in clean,
dry, protected areas.

CLEANING: Blow out the generator and controls peri­odically with low pressure air. Do this at least once a
week in particularly dirty areas.

BRUSH REMOVAL AND REPLACEMENT: See
Figure D.6. It’s normal for the brushes and slip rings
to wear and darken slightly. Inspect the brushes
when a generator overhaul is necessary. Remove the
brushes and clean the slip rings with fine grit sand­paper.

CAUTION

Do not attempt to polish slip rings while the engine is
running.

FIGURE D.6 – BRUSH REMOVAL AND REPLACEMENT

4

2

To reinstall the brushes, press them upward and slide
a cable tie or wooden stick through the brush
holder tabs. Install the brush holder into the bearing
end bracket and secure with the screws previously
removed. Remove the cable tie or wooden stick and
the brushes will seat onto the slip rings.

RECEPTACLES: Keep the electrical receptacles in
good condition. Remove any dirt, oil, or other debris
from their surfaces and holes.

CABLE CONNECTIONS: Check the welding cable
connections at the weld output terminals often. Be
sure that the connections are always firm.

6

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3

5

1

1. GENERATOR END BRACKET

2. BRUSH HOLDER ASSEMBLY

3. COVER

4. SCREWS (2)

5. BRUSHES

6. CABLE TIE

WELDANPOWER 125

D-6 D-6

MAINTENANCE

FIGURE D.6 – MAJOR COMPONENT LOCATIONS

5

6

8

7

1

3

4

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2

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

WELDANPOWER 125

Section E-1 Section E-1

TABLE OF CONTENTS

-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 – WELDANPOWER 125 BLOCK LOGIC DIAGRAM

ENGINE

MAGNETO

MECHANICAL

ROTATION

ROTOR
SLIP
RINGS

CAPACITORS

OUTPUT

RECTIFIER

BRIDGE

STATOR

ROTOR

STATOR

CHOKE

POSITIVE

OUTPUT

TERMINAL

NEGATIVE

OUTPUT

TERMINAL



CURRENT

TRANSFORMER

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IDLER

SOLENOID

IDLER

P.C. BOARD

RHEOSTAT

IDLE

SWITCH

+

HOUR
METER

FIELD

RECTIFIER

BRIDGE

115 AND 230 VAC

RECEPTACLES

E-2 E-2

OPERATION

FIGURE E.2 – ENGINE, EXCITATION, ROTOR AND STATOR

ENGINE

MAGNETO

IDLER

SOLENOID

P.C. BOARD

IDLER

MECHANICAL

ROTATION

ROTOR
SLIP

RINGS

CAPACITORS

RHEOSTAT

IDLE

SWITCH

+

HOUR

METER

OUTPUT

RECTIFIER

BRIDGE

FIELD

RECTIFIER

BRIDGE

STATOR

ROTOR

STATOR

CHOKE

115 AND 230 VAC

RECEPTACLES

POSITIVE

OUTPUT

TERMINAL

NEGATIVE

OUTPUT

TERMINAL



CURRENT

TRANSFORMER

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 configu­ration. This excitation (“flashing”) voltage magnetizes
the rotor lamination. The rotor is mechanically cou­pled to the engine. The rotating magnet induces a
voltage in the stationary windings of the main alterna­tor (stator).

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Three separate and isolated windings are incorporated
in the stator lamination assembly. Each winding set
has a different number of turns, producing different
magnitudes of AC output voltages. The three wind­ings are the weld winding, the auxiliary power winding
and the field feedback winding. The field feedback
winding provides rotor current during machine opera­tion, and, through the idle switch, supplies power to
the idler board. The output of the WELDANPOWER
125 is dependent on two criteria: the engine RPM and
the amount of current in the rotor winding.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

WELDANPOWER 125

E-3 E-3

OPERATION

FIGURE E.3 – ROTOR FIELD FEEDBACK, AUXILIARY POWER AND ENGINE IDLE CONTROL

ENGINE

MAGNETO

IDLER

SOLENOID

P.C. BOARD

IDLER

MECHANICAL

ROTATION

ROTOR
SLIP

RINGS

CAPACITORS

RHEOSTAT

IDLE

SWITCH

+

HOUR

METER

OUTPUT

RECTIFIER

BRIDGE

FIELD

RECTIFIER

BRIDGE

STATOR

ROTOR

STATOR

CHOKE

115 AND 230 VAC

RECEPTACLES

POSITIVE

OUTPUT

TERMINAL

NEGATIVE

OUTPUT

TERMINAL



CURRENT

TRANSFORMER

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. The DC output of the
bridge is filtered by the field capacitor and controlled
by the output rheostat. This filtered and controlled
feedback voltage is fed to the rotor winding via the
brush and slip ring configuration. As the feedback
voltage is increased or decreased, the outputs of the
weld and auxiliary windings are likewise increased or
decreased.

The hour meter is also powered by the field rectifier
bridge. When field voltage is present, the hour meter
will run.

When full field voltage is applied to the rotor and the
engine is running at high speed (3700 RPM), a 230VAC
voltage is developed in the stator auxiliary winding.
This winding is tapped. Each half of this winding pro­vides 115 VAC to each side of the 115V duplex recep­tacle. The two voltages (115VAC and 230VAC) are

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connected to the appropriate receptacles and offer
4500 watts (total) of AC power.

The idler solenoid is mechanically connected to the
engine throttle linkage. The field winding provides
power for the idler P.C. board and also to the idler
solenoid, which brings the engine to a low idle state.
When output current, either weld or auxiliary , is sensed
by the current transformer, the P.C. board deactivates
the idler solenoid, and the engine returns to high RPM.

AUXILIARY POWER
OVERCURRENT PROTECTION

The 4500 watt auxiliary power winding and circuitry is
protected from an overload condition by two 20 amp
circuit breakers. The circuit breakers are located
below the output receptacles. They can be manually
reset.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

WELDANPOWER 125

E-4 E-4

OPERATION

FIGURE E.4 – WELD WINDING, OUTPUT RECTIFIER AND CHOKE

ENGINE

MAGNETO

IDLER

SOLENOID

P.C. BOARD

IDLER

MECHANICAL

ROTATION

ROTOR
SLIP
RINGS

CAPACITORS

RHEOSTAT

IDLE

SWITCH

+

HOUR

METER

OUTPUT

RECTIFIER

BRIDGE

FIELD

RECTIFIER

BRIDGE

STATOR

ROTOR

STATOR

CHOKE

115 AND 230 VAC

RECEPTACLES

POSITIVE

OUTPUT

TERMINAL

NEGATIVE

OUTPUT

TERMINAL



CURRENT

TRANSFORMER

WELD WINDING, OUTPUT
RECTIFIER AND CHOKE

The AC voltage developed in the stator weld winding
is delivered through the current transformer to the out­put rectifier bridge, where the AC voltage is rectified to
a DC voltage. The DC current path from the output of
the rectifier bridge is through the choke, where the DC
is filtered, to the negative and positive output termi­nals.

The WELDANPOWER 125 provides 125 amps of con­stant current DC welding for stick electrodes.

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

WELDANPOWER 125

Section F-1 Section F-1

TABLE OF CONTENTS

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” Circuit Test.........................................................................................F-23

Engine Throttle Adjustment Test...................................................................................F-26

Oscilloscope Waveforms

Normal Open Circuit Weld Voltage Waveform..............................................................F-31

Normal Open Circuit Voltage Waveform (115 VAC Supply)..........................................F-32

Typical Weld Output Waveform - Machine Loaded......................................................F-33

Abnormal Open Circuit Weld Voltage Waveform..........................................................F-34

Replacement Procedures

Brush Removal and Replacement ................................................................................F-35

Rheostat Removal and Replacement ..........................................................................F-38

Field Capacitor Removal and Replacement .................................................................F-40

Field Diode Bridge Removal and Replacement............................................................F-42

Idler Printed Circuit Board Removal and Replacement ................................................F-45

Output Rectifier Bridge Removal and Replacement.....................................................F-47

Output Choke Removal and Replacement...................................................................F-50

Stator/Rotor Removal and Replacement (Kit S20925).................................................F-53

Retest After Repair ..............................................................................................................F-59

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WELDANPOWER 125

F-2 F-2

TROUBLESHOOTING & REPAIR

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

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.

This Troubleshooting Guide is provided to help
you locate and repair possible machine malfunc­tions. Simply follow the three-step procedure
listed below.

Step 1. LOCA TE PROBLEM (SYMPTOM). Look
under the column labeled “PROBLEM (SYMP­TOMS). This column describes possible symp­toms that the machine may exhibit. Find the list­ing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into three main categories: Output Problems,
Engine Problems, and Welding Problems.

Step 2. PERFORM EXTERNAL TESTS. The
second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external
possibilities that may contribute to the machine
symptom. Perform these tests/checks in the
order listed. In general, these tests can be con­ducted without removing the case wrap-around
cover.

Step 3. PERFORM COMPONENT TESTS. The
last column, labeled “Recommended Course of
Action” lists the most likely components that may
have failed in your machine. It also specifies the
appropriate test procedure to verify that the sub­ject component is either good or bad. If there are
a number of possible components, check the
components in the order listed to eliminate one
possibility at a time until you locate the cause of
your problem.

All of the referenced test procedur es referr ed to in
the Troubleshooting Guide are described in detail
at the end of this chapter. Refer to the
Troubleshooting and Repair Table of Contents to
locate each specific Test Procedure. All of the
referred to test points, components, terminal
strips, etc., can be found on the referenced elec­trical wiring diagrams and schematics. Refer to
the Electrical Diagrams Section Table of Contents
to locate the appropriate diagram.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 216-383-2531 or 1-800-833-9353.

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CAUTION

WELDANPOWER 125

F-3 F-3

TROUBLESHOOTING & REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING

ELECTRIC SHOCK can kill.

Have an electrician install and service
this equipment. Tur n the machine OFF
before working on equipment. Do not
touch electrically hot parts.

Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob­lems when troubleshooting and replacing PC boards,
please use the following procedure:

1. Determine to the best of your technical ability that
the PC board is the most likely component caus­ing the failure symptom.

2. Check for loose connections at the PC board to
assure that the PC board is properly connected.

3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read the
warning inside the static resistant bag and perform
the following procedures:

PC Board can be damaged by
static electricity.

• Remove your body’s static charge
before opening the static-shield­ing bag. Wear an anti-static wrist

ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations

Reusable
Container
Do Not Destroy

strap. For safety, use a 1 Meg
ohm resistive cord connected to a
grounded part of the equipment
frame.

• If you don’t have a wrist strap,
touch an unpainted, grounded,
part of the equipment frame.
Keep touching the frame to pre­vent static build-up. Be sure not
to touch any electrically live parts
at the same time.

• Remove the PC Board from the static-shielding bag
and place it directly into the equipment. Don’t set
the PC Board on or near paper, plastic or cloth which
could have a static charge. If the PC Board can’t be
installed immediately, put it back in the static­shielding bag.

• 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.

4. Test the machine to determine if the failure symp-

tom has been corrected by the replacement PC
board.

NOTE: Allow the machine to heat up so that all elec-

trical components can reach their operating
temperature.

5. Remove the replacement PC board and substitute

it with the original PC board to recreate the original
problem.

a. If the original problem does not reappear

by substituting the original board, then the
PC board was not the problem. Continue
to look for bad connections in the control
wiring harness, junction blocks, and termi­nal strips.

b. If the original problem is recreated by the

substitution of the original board, then the
PC board was the problem. Reinstall the
replacement PC board and test the
machine.

6. Always indicate that this procedure was followed

when warranty reports are to be submitted.

NOTE: Following this procedure and writing on the

warranty report, “INSTALLED AND SWITCHED
PC BOARDS TO VERIFY PROBLEM,” will help
avoid denial of legitimate PC board warranty
claims.

• T ools which come in contact with the PC Boar d must
be either conductive, anti-static or static-dissipative.

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WELDANPOWER 125

F-4 F-4

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

Major physical or electrical dam­age is evident.

No weld output and no auxiliary power. Engine operates normally.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Contact your local Lincoln
Authorized Field Service
Facility.

1. Check brushes for wear. See
the Maintenance section of
this manual.

2. Check for loose or faulty con­nections at brush holders.

RECOMMENDED
COURSE OF ACTION

1. Contact The Lincoln Electric
Service Dept. [phone] or
1-800-833-9353 (WELD).

1. Perform the Rotor Voltage
Test.

2. If the rotor voltage is low or
missing, check for the proper
flashing current. Perform the
Rotor Flashing Circuit Test.

3. Perform the Rotor Resistance
Test.

4. The field capacitor (C1) or recti­fier bridge (D1) may be faulty.
Test or replace.

5. Test the rheostat (R1). Normal
resistance is 3.3 ohms.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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CAUTION

WELDANPOWER 125

F-5 F-5

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

No weld output, the auxiliary
power (230-115VAC) operates nor­mally. Engine runs normally.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Check the open circuit voltage
(OCV) at the welder output ter­minals. Normal is 75 to 82VDC
with engine at high idle (3750
RPM) and the output rheostat at
maximum. If the correct OCV is
present, go to Step 3, below.

2. If the open circuit voltage is
NOT present at the welder out­put terminals, contact your
local Lincoln Electric Authorized
Field Service Facility.

3. Check the welding cables,
clamps and electrode holder for
loose or broken connections.

RECOMMENDED
COURSE OF ACTION

1. Check the continuity (low resis­tance) from the positive output
terminal, through the choke
(L1), to the positive side of the
output rectifier bridge (D2). See
Wiring Diagram.

2. Check the continuity (zero
ohms) from the negative output
terminal to the negative side of
the output rectifier bridge (D2).
See Wiring Diagram.

3. Perform the Output Rectifier
Bridge Test.

4. Perform the Main Stator

Winding Test.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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CAUTION

WELDANPOWER 125

F-6 F-6

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

No auxiliary power – welding out­put is normal – engine runs nor­mally.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Make sure that the control
rheostat (R1) is set at maxi­mum.

2. Check for a loose or faulty plug
at the power receptacle.

3. If the machine is equipped with
circuit breakers, check and
reset if tripped.

RECOMMENDED
COURSE OF ACTION

1. Check the auxiliary power
receptacles and associated
wires for loose or faulty con­nections.

2. Check the continuity (zero
ohms) of leads #3, #5, and #6
from the receptacles to the
main stator windings. See
Wiring Diagram.

3. Make sure lead #5 is grounded
to the machine frame (zero
ohms).

4. Perform the Main Stator

Winding Test.

If for any reason you do not understand the test procedures or ar e unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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CAUTION

WELDANPOWER 125

F-7 F-7

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

Low weld output and low auxiliary output.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. The generator brushes may be
worn. See the Maintenance
section of this manual or con­tact your local Lincoln Electric
Authorized Field Service
Facility.

2. The engine RPM may be low.

RECOMMENDED
COURSE OF ACTION

1. Perform the Rotor Voltage

Test.

2. If the rotor voltage is low, the
field capacitor (C1) or the field
rectifier bridge (D1) may be
faulty. Test or replace.

3. Check the rheostat (R1).
Normal resistance is 3.3 ohms.
See Wiring Diagram.

4. The rotor may be faulty.
Perform the Rotor Resistance

Test.

5. The engine RPM may be low.
Perform the Engine Throttle

Adjustment Test.

6. If the engine idle RPM is okay,
the engine may have lost
horsepower and be in need of
major repair.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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CAUTION

WELDANPOWER 125

F-8 F-8

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

ENGINE PROBLEMS

Engine will not start. 1. Make sure the RUN/STOP

Switch is in the “RUN” position.

2. Make sure the fuel shut off valve
is in the open position.

3. Make sure the engine has ade­quate fuel and oil.

4. Adjust the choke to prevent car­buretor flooding.

5. Check the spark plug wire for
loose or faulty connections.

Engine runs erratic or stops run­ning.

1. The oil level may be low, acti­vating the engine oil level shut­down system. Check oil level.

2. Check the spark plug wire for
loose or faulty connection.

3. The spark plug may be faulty.
Replace.

4. The fuel and air mixture may be
out of adjustment. Consult the
Briggs & Stratton Owner’s
Manual.

RECOMMENDED
COURSE OF ACTION

1. Check the fuel line for breaks or
obstructions.

2. The spark plug may be faulty.
Replace.

3. Service the engine as outlined
in the Maintenance section of
this manual.

4. The engine ignition module may
be faulty. Consult Briggs &
Stratton Service.

1. If the oil level is correct, the oil
level shutdown switch may be
faulty . Remove the lead running
from the oil level switch to the
ignition module. If the engine
runs normally, the oil level
switch is faulty. Replace. DO
NOT OPERATE THE ENGINE
WITHOUT OIL LEVEL PRO­TECTION.

2. The engine may require service
to the head or carburetor.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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5. The fuel supply may be conta­minated with water.

CAUTION

WELDANPOWER 125

F-9 F-9

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

Engine will NOT idle down to low speed.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

ENGINE PROBLEMS

1. Make sure the idler control
switch is in the “AUTO” idle
position.

2. Remove any external load on
the welder terminals or auxiliary
power receptacles.

RECOMMENDED
COURSE OF ACTION

1. With the idler control switch in
the “AUTO” position and all
external loads removed, check
for 12VDC at leads #208 and
#209. See Wiring Diagram. If
the 12VDC is present and the
idler solenoid does not activate,
the solenoid may be faulty.
Replace.

2. If the 12VDC is NOT present at
leads #208 and #209, perform
the Main Stator Winding Test.

3. Check leads #15A (at stator) to
#16 (at idler P.C. board) for con­tinuity (zero ohms). Check
leads #9A (at stator) to #9B (at
idler P.C. board) for continuity
(zero ohms). See Wiring
Diagram.

CAUTION

4. The idler P.C. board may be
faulty. Replace.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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WELDANPOWER 125

F-10 F-10

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

Engine idles down to low idle but will not stay at low idle.

Engine will not go to high idle when
attempting to weld or when the
auxiliary power is loaded. Welding
output and auxiliary power output
is normal when idler control switch
is in the “HIGH” position.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

ENGINE PROBLEMS

1. Remove any external load on
the welder terminals or auxiliary
power receptacles.

2. The engine low idle RPM may
be set too low. Contact your
local Lincoln Electric Field
Service Facility.

1. Check work and electrode
cables for loose or faulty con­nections.

2. The mechanical linkage be­tween the solenoid and engine
may be stuck.

RECOMMENDED
COURSE OF ACTION

1. The engine low idle RPM may
be set too low. Perform the

Engine Throttle Adjustment
Test.

2. With the idler control switch in
the “AUTO” position and all
external loads removed, check
for 12VDC at leads #208 and
#209. See Wiring Diagram. If
the 12VDC is present and the
solenoid does not stay activat­ed, the solenoid may be faulty.
Replace.

1. Locate plug J2 on the control
board. With a load on the
machine, measure the AC volt­age across the two leads in plug
J2. Normal is 1.0 VAC mini­mum. If the correct voltage is
present, the idler P.C. board
may be faulty. Replace.

If for any reason you do not understand the test procedures or ar e unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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2. If the correct voltage is NOT
present at Plug J2 leads, check
the continuity of the leads from
the current transformer to plug
J2. See Wiring Diagram.

3. The current transformer may be
faulty. Replace.

CAUTION

WELDANPOWER 125

F-11 F-11

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

Engine will not go to high idle when
attempting to weld. Welding output
is normal when the idler control
switch is in the “HIGH” position.
Automatic idle function works
properly when the auxiliary power
is loaded.

Engine will not go to high idle when
using the auxiliary power. Auxiliary
power output is normal when the
idler control switch is in the “HIGH”
position. Automatic idle function
works properly when the welding
output is loaded.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

ENGINE PROBLEMS

1. Make sure the welding cables
and connections are tight.

1. Make sure that the auxiliary
load is more than 100 watts.

2. Check for loose or faulty con­nections at the auxiliary output
receptacles.

RECOMMENDED
COURSE OF ACTION

1. Make sure the #W1 lead is
looped through the current
transformer. See Wiring
Diagram.

2. Check for loose or faulty con­nections on the heavy current
carrying leads connected to the
output terminals, the choke (L1)
and the output rectifier bridge

(D2).

1. Make sure that leads #3A and
#6A are looped through the cur­rent transformer in the proper
direction. See Wiring Diagram.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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CAUTION

WELDANPOWER 125

F-12 F-12

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS
(SYMPTOMS)

The welding arc is “cold.” The engine runs normally . The auxiliary power functions normally.

POSSIBLE AREAS OF
MISADJUSTMENT(S)

ENGINE PROBLEMS

1. Check for loose or faulty con­nections at the weld output ter­minals and welding cable con­nections.

2. The welding cable may be too
long or coiled, causing an
excessive voltage drop.

RECOMMENDED
COURSE OF ACTION

1. With the output control at max­imum, check for the correct
open circuit voltage (OCV) at
the welder output terminals (75

- 82 VDC). If the correct open
circuit voltage is present at the
output terminals, check for
loose connections on the heavy
current carrying leads inside the
WELDANPOWER 125. See
Wiring Diagram.

2. If the OCV is low at the welder
output terminals, perform the

Engine Throttle Adjustment
Test.

3. Perform the Output Rectifier
Bridge Test.

4. Check for shorted or grounded
windings in the choke (L1).

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con­tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
216-383-2531 or 1-800-833-9353.

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CAUTION

WELDANPOWER 125

F-13 F-13

TROUBLESHOOTING & REPAIR

ROTOR VOLTAGE TEST

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

TEST DESCRIPTION

This test will determine if the correct DC voltage is being applied to the rotor at maximum
engine speed (3700 RPM). This information will aid the technician in determining if the gen­erator field is operating properly.

MATERIALS NEEDED

Volt/Ohmmeter
5/16” Nut driver
Wiring Diagram

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WELDANPOWER 125

F-14 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. Remove the top cover.

2. Start the machine and run it at high idle.
Set the output control (rheostat) at the
MAXIMUM setting.

GROUND STUD

5. Check the voltage reading on the volt/ohm­meter. It should read 40 - 47 VDC.

6. If the voltage is low or not present, the gen­erator field circuit is not functioning cor­rectly. Proceed with the Rotor Resistance
Test. C1, R1, or D1 may also be faulty.

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3. Set the volt/ohmmeter at the DC position.

4. Place the positive probe on lead #202 (two
red wires joined together) where it con­nects at the back of the rheostat. See
Figure F.1 for location. Place the negative
probe on the machine ground stud or any
other good, unpainted ground.

WELDANPOWER 125

7. If rotor voltage is correct, the generator
field is okay. Replace the top cover on the
control box. Tighten the 8 sheet metal
screws with the 5/16” nut driver.

F-15 F-15

TROUBLESHOOTING & REPAIR

ROTOR RESISTANCE TEST

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

TEST DESCRIPTION

This test will determine if there is a shorted winding in the rotor or if the rotor is grounded.

MATERIALS NEEDED

Volt/Ohmmeter
1/4” Nut driver
Small slot head screw driver
Wiring Diagram

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WELDANPOWER 125

F-16 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.

3. Isolate the rotor electrically by removing
the generator brushes. Refer to Figure F.2
as you perform the remaining steps.

4. Open the brush holder assembly cover.
Squeeze the 2 tabs and depress the cover
at the top with a screw driver or your fin­gernail. The cover will drop open on its
bottom hinge.

5. With the 1/4” nut driver, remove the 2
screws that hold the brush holder assem­bly in place.

6. Slide the brush holder assembly out and
lay it aside, held by the 2 wires attached.

7. Measure the resistance across the rotor
slip rings.

A. Set the ohmmeter on the low scale

(X1).

B. Place one meter probe on one of the

rotor slip rings. Place the other probe
on the other slip ring.

C. Check the resistance across the slip

rings. It should read 7 - 8 ohms.

8. Measure the resistance to ground.

A.. Set the ohmmeter on the high scale

(X100,000).

B. Place one probe on either of the slip

rings. Place the other probe on any
good, unpainted ground. Use the
ground stud or the rotor thru-bolt.

C. Check the resistance. It should read

very high, at least .5 megohm
(500,000 ohms).

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If the resistance checks meet the specifica­tions, then the rotor is okay.

WELDANPOWER 125

F-17 F-17

TROUBLESHOOTING & REPAIR

ROTOR RESISTANCE TEST (continued)

FIGURE F.3 – BRUSHES RETAINED WITH CABLE TIE

CABLE

TIE

BRUSHES

9. Reinstall the brush holder assembly after
the test. Depress the spring-loaded brush­es into the holder and slip a suitable non­metallic, fairly stiff retainer through the slots
at the top and bottom of the holder. A
cable tie works well; see Figure F.3. This
will hold the brushes up so that you can
easily install the holder.

10. Slip the holder into position in the genera-

tor end bracket. Be careful not to loosen
the 2 attached wires.

11. Reinstall and tighten the 2 screws with the

1/4” nut driver.

12. Slowly remove the non-metallic retainer

from the brush holder and let the brushes
snap back against the slip rings.

13. Snap the brush holder cover back into

position.

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WELDANPOWER 125

F-18 F-18

TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER BRIDGE TEST

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

TEST DESCRIPTION

This test will determine if there are faulty diodes in the output rectifier bridge.

MATERIALS NEEDED

Volt/Ohmmeter (Diode Tester)
7/16" Wrench
5/16" Nut driver
Wiring Diagram

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WELDANPOWER 125

F-19 F-19

TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER BRIDGE TEST (continued)

FIGURE F.4 - OUTPUT RECTIFIER BRIDGE

W2

W1

Strap

203

204

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. Remove the top cover.

4. Locate the output rectifier bridge.

5. With the 7/16" wrench, remove the nuts
and washers that hold the four diode pigtail
leads and the heavy current carrying leads
to the studs located at the front of the rec­tifier bridge assembly. Note lead place­ment for reassembly. See Figure F.4.

6. Electrically isolate the diode pigtails.

7. With the volt/ohmmeter or diode tester,
check the resistance of each of the four
diodes from their pigtail leads to their
respective heat sinks. Alternate placement
of the test probes. Resistance should be
high in one direction and low in the other.

8. Replace any shorted or open diodes.

9. Reassemble the heavy current carrying
leads and pigtails to their respective
studs. The proper fastener sequence is:
pigtail - lead - flat washer - lock washer ­nut.

10. Replace the top cover on the control box.
Tighten the 8 sheet metal screws with the
5/16" nut driver.

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WELDANPOWER 125

F-20 F-20

TROUBLESHOOTING & REPAIR

MAIN STATOR TEST

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

TEST DESCRIPTION

This test will determine if the main stator is generating the proper AC output voltages.

MATERIALS NEEDED

Volt/Ohmmeter
5/16" Nut driver
5/16" Open end or box wrench
Wiring Diagram

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WELDANPOWER 125

F-21 F-21

TROUBLESHOOTING & REPAIR

MAIN STATOR TEST (continued)

FIGURE F.5 - LOCATION OF LEADS W1 AND W2

203

Strap

W2

W1

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, remove the 6
sheet metal screws that hold the control
panel in place. Move the panel aside to
provide access to the test points. Be sure
to secure the panel while the engine in run­ning during the test.

WARNING

MOVING PARTS can injure.

Keep away from moving parts.

204

WARNING

ENGINE EXHAUST can kill.

Use in open, well ventilated
areas or vent exhaust to the
outside.

3. Start the engine and run it at High Idle
(3700 - 3800 RPM). Set the Output Control
(R1) at maximum. Remove all external
loads from the machine.

3. Locate leads W1 and W2 at the output rec­tifier bridge studs. See Figure F.5.

4. Check for 80 VAC at leads W1 to W2.

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WELDANPOWER 125

F-22 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 – Brown

5. Locate the 6 pin molex type connector
from the main stator.

6. Check for 240 - 260 VAC at leads #6A to
#3A. See Figure F.6. You may want to shut
off the engine, insert the test probes into
the molex plug, then restart the engine.
Cut any necessary cable ties to perform the
test.

NOTE: Insert the probes on the STATOR side

of the plug. This will eliminate the
possibility of problems in the plug
itself.

7. Check for 120 - 130 VAC at leads #5A to
#3A. See Figure F.6.

8. At the field rectifier diode bridge, check for

37.5 VAC at leads #9A (Brown) to #7A
(Blue). See Figure F.7 and the Wiring
Diagram. You may check these leads at
the molex plug; however, it's best to check
them at the rectifier bridge.

TO STATOR

FIGURE F.7

DIODE BRIDGE LEAD ASSIGNMENTS

7A (Blue)

201 (Black)
201C (Black)

9. Check for 21.5 VAC at leads #9A (Brown)

10. If any ONE of the voltage readings are

11. If ALL the voltage readings are incorrect,

12. After the problem has been repaired,

13. Install the control panel with the 6 sheet

14. Replace the top cover on the control box.

–

to #15A (Yellow). See Figure F.6.

incorrect, the main stator may be faulty.

the problem may be the engine RPM or
rotor field problems.

replace any cable ties that were cut for the
test.

metal screws. Use the 5/16" nut driver
and 5/16" wrench.

Tighten the 8 sheet metal screws with the
5/16" nut driver.

200 (Red)

200C (Red)

+

9A (Brown)

9B (Brown)

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WELDANPOWER 125

F-23 F-23

TROUBLESHOOTING & REPAIR

ROTOR “FLASHING” CIRCUIT TEST

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

TEST DESCRIPTION

This test will determine if the engine magneto is supplying the proper "flashing" current to the
rotor.

MATERIALS NEEDED

Volt/Ohmmeter
5/16" Nut driver
DC Ammeter
Wiring Diagram

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WELDANPOWER 125

F-24 F-24

TROUBLESHOOTING & REPAIR

ROTOR “FLASHING” CIRCUIT TEST (continued)

FIGURE F.8 - BRUSH HOLDER LEADS 201A(-) AND 202B (+)

201A(-)

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. Remove the top cover.

2. Locate and remove lead #201A from the
brush holder. See Figure F.8 for location.

FIGURE F.9 - DIODE BRIDGE LEAD ASSIGNMENTS

7A (Blue)

3. Connect the negative (-) lead of the DC
ammeter to lead #201A and the positive (+)
lead to the brush holder.

4. Remove lead #7A from field diode bridge
rectifier D1. See Figure F.9. Electrically
isolate the lead.

200 (Red)

200C (Red)

+

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201 (Black)
201C (Black)

9A (Brown)
9B (Brown)

–

WELDANPOWER 125

F-25 F-25

TROUBLESHOOTING & REPAIR

ROTOR “FLASHING” CIRCUIT TEST (continued)

FIGURE F.10 - IDLER P.C. BOARD PIN ASSIGNMENTS

204 (BLACK)
202A (RED)
208 (BROWN)
209 (BROWN)

J1J2

WP125 IDLER

200A (WHITE)

TO

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.

5. Start the engine and run it at High Idle
(3700 - 3800 RPM).

6. The DC ammeter should read between

0.22 and 0.30 amps.

7. If the DC ammeter reads 0.0 amps, check
for flashing voltage between lead #202B
from the brush holder and case ground
(lead #201). See Figure F.8 and the Wiring
Diagram. Normal flashing voltage is 2.05
VDC.

M17578

16 (BLACK)

9B (BROWN)

14 (WHITE)
203 (RED)

8. If normal flashing voltage is present, per­form the Rotor Resistance Test. Also be
sure that all #201 leads have continuity
(zero ohms) to case ground.

9. If normal flashing voltage is NOT present
from lead #202 to case ground, check the
continuity of lead #202 to the idler P.C.
board. Also check the continuity of lead
#14 from the engine magneto to the P.C.
board. See Figure F.10 and the Wiring
Diagram.

10. If the above continuity checks are good,
run the engine at high idle (3700 - 3800
RPM). Check for an AC voltage from lead
#14 to case ground. Normal is 3.30 VAC.
If a low or zero AC voltage is indicated,
the engine magneto may be faulty.
Replace.

11. If the AC voltage reading from step 9 is
normal, the idler P.C. board may be faulty.
Replace the idler P.C. board.

12. After the problem has been repaired,
replace the top cover on the control box.
Tighten the 8 sheet metal screws with the
5/16" nut driver.

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WELDANPOWER 125

F-26 F-26

TROUBLESHOOTING & REPAIR

ENGINE THROTTLE ADJUSTMENT TEST

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

TEST DESCRIPTION

If the machine output is low, this test will determine whether the gasoline engine high idle
speed is set for the correct maximum RPM. It will also let you adjust the low idle speed.

MATERIALS NEEDED

7/16" Open end or box wrench
Slot head screw driver
Dowel rod (approximately 12") or long-blade screw driver
Frequency counter or strobe-tach
Black or red marking pencil

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WELDANPOWER 125

F-27 F-27

TROUBLESHOOTING & REPAIR

ENGINE THROTTLE ADJUSTMENT TEST (continued)

FIGURE F.11 - BLOWER PADDLE MARKED FOR STROBE-TACH METHOD

Mark

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.

2. With the black or red marking pencil, place
a mark on one of the blower paddles,
which can be reached through the vent
slots in the end bracket. See Figure F.11.

3. Connect the strobe-tach according the
manufacturer's instructions.

WARNING

MOVING PARTS can injure.

Keep away from moving parts.

WARNING

ENGINE EXHAUST can kill.

Use in open, well ventilated
areas or vent exhaust to the
outside.

4. Reconnect the spark plug wire and start
the engine. Direct the strobe-tach light on
the blower paddle and synchronize it to the
rotating mark.

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WELDANPOWER 125

F-28 F-28

TROUBLESHOOTING & REPAIR

ENGINE THROTTLE ADJUSTMENT TEST (continued)

FIGURE F.12 - IDLE SPEED ADJUSTMENT SCREW LOCATIONS

HIGH IDLE INCREASE SPEED SCREW

LOW IDLE SPEED SCREW

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 sev­eral turns. Turn the High Idle
Decrease Speed screw clockwise until
the engine speed is between 3700 and
3800 RPM. See Figure F.12.

Next, turn the High Idle Increase
Speed screw clockwise until the
screw contacts the tab on the
Governor Control Lever. Do NOT
tighten the screw any further, as this
may cause the tab to bend. See Figure
F.12.

b. If the engine speed is below 3700

RPM, turn the High Idle Decrease
Speed screw counter-clockwise sev­eral turns. Turn the High Idle Increase
Speed screw clockwise until the
engine speed is between 3700 and
3800 RPM. See Figure F.12.

Next, turn the High Idle Decrease
Speed screw clockwise until the
screw contacts the tab on the
Governor Control Lever. Do NOT
tighten the screw any further, as this
may cause the tab to bend. See Figure
F.12.

HIGH IDLE DECREASE SPEED SCREW

GOVERNOR CONTROL LEVER

CARBURETOR THROTTLE LEVER

c. After the adjustments are made,

try to move the Governor Control
Lever. There should be no move­ment. The two high idle speed
screws are designed to work
against opposite sides of the
Governor Control Lever tab so that
no movement (and therefore no
increase in speed) is possible.

6. 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. Adjust the Low
Idle Speed screw until the engine speed is
2075 + 75 RPM.

Set the Idler Switch on AUTO. The engine
should go to low idle in about 12 seconds.

Use the 3/8" wrench to turn the adjustment
nut on the idler solenoid plunger, which
changes the amount of throw in the gover­nor arm. See Figure F.13. for location of
the adjustment nut. Adjust the nut until the
tach reads between 2250 and 2500 RPM.

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WELDANPOWER 125

F-29 F-29

TROUBLESHOOTING & REPAIR

ENGINE THROTTLE ADJUSTMENT TEST (continued)

FIGURE F.13 - LOW IDLE ADJUSTMENT NUT ON IDLER SOLENOID

Solenoid

Housing

3/8" Low Idle

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
115 VAC auxiliary receptacles.

Adjustment

Nut

Rod

b. If the counter reading is below 60.8

Hz, turn the High Idle Decrease Speed
screw counter-clockwise several
turns. Turn the High Idle Increase
Speed screw clockwise until the
engine speed is between 60.8 and

62.5 Hz. See Figure F.12.

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2. Start the engine and check the frequency
counter . With the Idler Switch set on HIGH,
the counter should read 60.8 to 62.5 Hz.
With the Idler Switch set on AUTO (and
after the machine has changed speeds,
about 12 seconds) the counter should read

35.8 to 37.5 Hz. If either of these readings
is wrong, adjust as follows:

3. ADJUST HIGH IDLE:

a. If the counter reading is above 62.5

Hz, turn the High Idle Increase Speed
screw counter-clockwise several
turns. Turn the High Idle Decrease
Speed screw clockwise until the
counter reading is between 60.8 and

62.5 Hz. See Figure F.12.
Next, turn the High Idle Increase

Speed screw clockwise until the
screw contacts the tab on the
Governor Control Lever. Do NOT
tighten the screw any further, as this
may cause the tab to bend. See Figure
F.12.

WELDANPOWER 125

Next, turn the High Idle Decrease
Speed screw clockwise until the
screw contacts the tab on the
Governor Control Lever. Do NOT
tighten the screw any further, as this
may cause the tab to bend. See Figure
F.12.

c. After the adjustments are made,

try to move the Governor Control
Lever. There should be no move­ment. The two high idle speed
screws are designed to work
against opposite sides of the
Governor Control Lever tab so that
no movement (and therefore no
increase in speed) is possible.

F-30 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 . Adjust
the Low Idle Speed screw until the fre­quency counter reading is 34.1 Hz.

Set the Idler Switch set on AUTO. The
engine should go to low idle in about 12
seconds.

Use the 3/8" wrench to turn the adjust­ment nut on the idler solenoid plunger,
which changes the amount of throw in the
governor arm. See Figure F.13 for loca­tion of the adjustment nut. Adjust the nut
until the frequency counter reads between

35.8 and 37.7 Hz.

5. After you set the low idle speed, set the

Idler Switch to HIGH and recheck the high
idle speed. Adjust if necessary.

Oscilloscope Method:

1. Connect the oscilloscope according to the

manufacturer's instructions. At 3700
RPM, the waveform should exhibit a peri­od of 16.2 milliseconds. Refer to the NOR­MAL OPEN CIRCUIT VOLTAGE WAVE­FORM (115 VAC SUPPLY) HIGH IDLE ­NO LOAD in this section of the manual. At
2200 RPM, the waveform should exhibit a
period of 27.3 milliseconds.

2. Start the engine and check the oscillo-

scope. With the Idler Switch set on HIGH,
the waveform should exhibit a period of

16.2 milliseconds. With the Idler Switch
set on AUTO (and after the machine has
changed speeds, about 12 seconds) the
waveform should exhibit a period of 27.3
milliseconds. If either of these readings is
wrong, adjust as follows:

3. ADJUST HIGH IDLE:

a. If the waveform period is less than

16.2 milliseconds, turn the High Idle
Increase Speed screw counter-clock­wise several tur ns. Turn the High Idle
Decrease Speed screw clockwise until
the waveform period is 16.2 millisec­onds. See Figure F.12.

Next, turn the High Idle Increase
Speed screw clockwise until the
screw contacts the tab on the
Governor Control Lever. Do NOT
tighten the screw any further, as this
may cause the tab to bend. See Figure
F.12.

b. If the waveform period is greater than

16.2 milliseconds, turn the High Idle
Decrease Speed screw counter-clock­wise several tur ns. Turn the High Idle
Increase Speed screw clockwise until
the waveform period is 16.2 millisec­onds. See Figure F.12.

Next, turn the High Idle Decrease
Speed screw clockwise until the
screw contacts the tab on the
Governor Control Lever. Do NOT
tighten the screw any further, as this
may cause the tab to bend. See Figure
F.12.

c. After the adjustments are made, try to

move the Governor Control Lever.
There should be no movement. The
two high idle speed screws are
designed to work against opposite
sides of the Governor Control Lever
tab so that no movement–(and there­fore no increase in speed–) is possible.

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.13. You can
also push the arm back with your hand,
but this is not recommended because you
could be burned by the hot muffler . Adjust
the Low Idle Speed screw until the wave­form period is approximately 29 millisec­onds.

Set the Idler Switch on AUTO. The engine
should go to low idle in about 12 seconds.

Use the 3/8" wrench to turn the adjust­ment nut on the idler solenoid plunger,
which changes the amount of throw in the
governor arm. See Figure F.13. for loca­tion of the adjustment nut. Adjust the nut
until the waveform period is 27.3 millisec­onds.

5. After you set the low idle speed, set the
Idler Switch to HIGH and recheck the high
idle speed. Adjust if necessary.

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WELDANPOWER 125

F-31 F-31

TROUBLESHOOTING & REPAIR

NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM

HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM

CH1

0 volts

50 volts

This is the typical output voltage gen­erated from a properly operating
machine. Note that each vertical
division represents 50 volts and that
each horizontal division represents 5
milliseconds in time.

Note: Scope probes connected at
machine output terminals.

5 ms

SCOPE SETTINGS

Volts/Div.....................50V/Div.

Horizontal Sweep.....5 ms/Div.

Coupling ............................DC

Trigger .........................Internal

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WELDANPOWER 125

F-32 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

CH1

0 volts

50 volts

This is the typical AC output voltage
generated from a properly operating
machine. Note that each vertical
division represents 50 volts and that
each horizontal division represents 5
milliseconds in time.

Note: Scope probes connected at
machine 115 VAC receptacle.

SCOPE SETTINGS

Volts/Div.....................50V/Div.

Horizontal Sweep.....5 ms/Div.

Coupling ............................DC

Trigger .........................Internal

5 ms

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WELDANPOWER 125

F-33 F-33

TROUBLESHOOTING & REPAIR

TYPICAL WELD OUTPUT WAVEFORM

MACHINE LOADED

CH1

0 volts

20 volts

5 ms

MACHINE LOADED TO 125 AMPS AT 25 VAC

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. The mahine
was loaded with a resistance grid
bank.

Note: Scope probes connected at
machine output terminals.

SCOPE SETTINGS

Volts/Div.....................20V/Div.

Horizontal Sweep.....5 ms/Div.

Coupling ............................DC

Trigger .........................Internal

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WELDANPOWER 125

F-34 F-34

TROUBLESHOOTING & REPAIR

ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM

HIGH IDLE – NO LOAD – OUTPUT CONTROL AT MAXIMUM

CH1

0 volts

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”
diode. Each vertical division repre­sents 50 volts and that each horizon­tal division represents 5 milliseconds
in time.

Note: Scope probes connected at
machine output terminals.

5 ms

SCOPE SETTINGS

Volts/Div.....................50V/Div.

Horizontal Sweep.....5 ms/Div.

Coupling ............................DC

Trigger .........................Internal

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WELDANPOWER 125

F-35 F-35

TROUBLESHOOTING & REPAIR

BRUSH REMOVAL AND REPLACEMENT

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in accessing the generator brushes for
maintenance or replacement.

MATERIALS NEEDED

Small slot head screw driver
1/4” Nut driver
Needle nose pliers

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WELDANPOWER 125

F-36 F-36

TROUBLESHOOTING & REPAIR

BRUSH REMOVAL AND REPLACEMENT (continued)

FIGURE F.14 - BRUSHES RETAINED 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 fin­gernail. The cover will drop open on its
bottom hinge.

3. With the 1/4” nut driver, remove the 2
screws that hold the brush holder assem­bly in place.

4. With the needle nose pliers, gently remove
the black and the red wires.

Note: The red wire is inboard. “RED” is
marked on the brush holder beside the termi­nal for the red wire.

5. To change the brushes, use the slot head
screw driver to pop off the plastic retainer
on the back of the brush holder assembly.

6. Remove the old brush assemblies and
insert the new ones. One corner of the ter­minal clip is beveled so that the brush can
go in only one way.

7. Snap the plastic retainer back onto the
brush holder. The brushes may need some
repositioning; wiggle them slightly to help
them seat properly on the slip rings.

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WELDANPOWER 125

F-37 F-37

TROUBLESHOOTING & REPAIR

BRUSH REMOVAL AND REPLACEMENT (continued)

PROCEDURE

8. To reinstall the brush holder assembly,
depress the spring-loaded brushes into
the holder and slip a suitable non-metal­lic, fairly stiff retainer through the slots at
the top and bottom of the holder. A cable
tie works well; see Figure F.14. This will
hold the brushes up so that you can eas­ily install the holder.

9. With the needle nose pliers, reinstall the
red and the black wires to the appropriate
terminals on the brushes. The red wire is
inboard.

10. Slip the holder into position in the genera­tor end bracket. Be careful not to loosen
the 2 attached wires.

(continued)

11. Reinstall and tighten the 2 screws with the
1/4” nut driver.

12. Slowly remove the non-metallic retainer
from the brush holder and let the brushes
snap back against the slip rings.

13. Check the wire connections or clearance
and tightness.

14. Snap the brush holder cover back into
position.

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WELDANPOWER 125

F-38 F-38

TROUBLESHOOTING & REPAIR

RHEOSTAT REMOVAL AND REPLACEMENT

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in accessing and removing the output control
rheostat for maintenance or replacement.

MATERIALS NEEDED

5/16” Nut driver
Small slot head screw driver
9/16” Open or box end wrench
5/16” Open or box end wrench
Needle nose pliers
Wiring Diagram

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WELDANPOWER 125

F-39 F-39

TROUBLESHOOTING & REPAIR

RHEOSTAT REMOVAL AND REPLACEMENT (continued)

FIGURE F.15 - RHEOSTAT REMOVAL

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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. Remove the top cover.

3. With the 5/16” nut driver and the 5/16”
wrench, remove the 6 screws that hold the
control panel in place. Move the panel
aside as far as the leads will allow.

4. With the small slot head screw driver,
loosen the screw that holds the knob to the
rheostat shaft. The shaft has a flat for
locating the knob at reassembly.

5. With a 9/16” open or box end wrench,
remove the nut that holds the rheostat to
the control panel. Support the rheostat
with your hand as you turn the nut. There
is a shake-proof washer under the nut.

6. Pull the rheostat back out of the control
panel and lay it out on its wires to loosen
the nuts that hold them.

7. With the 5/16” open or box end wrench,
remove the brass nuts from the wire termi­nals. Support the terminals as you turn the
wrench to avoid ripping the terminals from
their foundations. Note the wire locations
for reassembly.

Note: The brass screws are double-nutted
with a shake-proof star washer under the
screw head.

WELDANPOWER 125

8. To reinstall the rheostat, replace each of
the brass screws. Place a shake-proof
star washer under the head, insert the
screw into the rheostat and tighten down
one nut. Replace the appropriate wires
and tighten down the second nut. Again,
support the terminals as you turn the
wrench to avoid ripping the terminals
from their foundations.

9. Reassemble the rheostat to the front of
the control panel. Line up the locating tab
on the rheostat with the slot on the con­trol panel hole.

10. Reassemble the shake-proof star washer
and nut and tighten securely with the
9/16” wrench.

11. Locate the flat spot on the shaft, line up
the knob locking screw, push the knob
onto the shaft and tighten the screw with
the small slot head screw driver.

12. Check the rheostat knob for proper rota­tion, minimum to maximum.

13. Replace the control panel and tighten the
6 sheet metal screws with the 5/16” nut
driver and 5/16” wrench.

14. Replace the top cover of the control box
and tighten the 8 sheet metal screws with
the 5/16” nut driver.

F-40 F-40

TROUBLESHOOTING & REPAIR

FIELD CAPACITOR REMOVAL AND REPLACEMENT

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in accessing and removing the field capacitor
for maintenance or replacement.

MATERIALS NEEDED

5/16” Nut driver
5/16” Wrench
Jumper wire with alligator clips on each end for discharging the field capacitor
Slot head screw driver
Needle nose pliers
Wiring Diagram

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WELDANPOWER 125

F-41 F-41

TROUBLESHOOTING & REPAIR

FIELD CAPACITOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.16 - DISCHARGING THE FIELD CAPACITOR

Attachment for

202

202B

(-)

Cable Tie

Capacitor

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. Remove the top cover.

3. With the 5/16” nut driver and 5/16” wrench,
remove the 6 screws that hold the control
panel in place. Move the panel aside as far
as the leads will allow.

4. Discharge the field capacitor by connecting
the jumper wire clips on the black and the
red wire terminals on the top of the capac­itor . See Figur e F.16. Leave the clips on for
at least 5 seconds, then remove.

5. The capacitor is mounted in a molded plas­tic holder. To remove it, pull out on the top
of the holder, then slide it upward.

Attachment for

201C
201B
201A

(+)

Jumper

6. Cut the tie wrap and snap the capacitor out
of the assembly.

7. Loosen the two screws on the top of the
capacitor. Leads #202B and #202 (Red)
attach to the positive (+) terminal. Leads
#201C, 201B and 201A (Black) attach to
the negaive (-) terminal.

8. To replace the capacitor, reattach the leads
to their respective terminals [202 and 202B
Red to positive (+); 201C, 201B and 201A
Black to negative (-)] and tighten the
screws securely. Snap the capacitor back
into the molded plastic holder and slide the
holder back into position in the panel.
Replace the tie wrap.

9. Replace the control panel and tighten the 6
sheet metal screws with the 5/16” nut dri­ver and 5/16” wrench. Replace the top
cover of the control box and tighten the 8
sheet metal screws with the 5/16” nut
driver.

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WELDANPOWER 125

F-42 F-42

TROUBLESHOOTING & REPAIR

FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in accessing and removing the field diode
bridge for maintenance or replacement.

MATERIALS NEEDED

5/16” Nut driver
11/32” Wrench
5/16” Wrench
Jumper wire with alligator clips on each end for discharging the field capacitor
Slot head screw driver
Needle nose pliers
Wiring Diagram

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WELDANPOWER 125

F-43 F-43

TROUBLESHOOTING & REPAIR

FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT (continued)

FIGURE F.17 - DISCHARGING THE FIELD CAPACITOR

Attachment for

202

202B

(-)

Cable Tie

Capacitor

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. Remove the top cover.

Attachment for

201C
201B
201A

(+)

Jumper

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3. With the 5/16” nut driver and the 5/16”
wrench, remove the 6 screws that hold the
control panel in place. Move the panel
aside as far as the leads will allow.

4. Discharge the field capacitor by connecting
the jumper wire clips on the black and the
red wire terminals on the top of the capac­itor . See Figur e F.17 for location. Leave the
clips on for at least 5 seconds, then
remove.

WELDANPOWER 125

F-44 F-44

TROUBLESHOOTING & REPAIR

FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT (continued)

FIGURE F.18 - FIELD DIODE BRIDGE LOCATION

200 (Red)

200C (Red)

7A (Blue)

+

201 (Black)
201C (Black)

9A (Brown)
9B (Brown)

–

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” wrench.

6. With the needle nose pliers, gently remove
the 7 wires from the diode bridge.

7. Replace the wires to their appr opriate loca­tions on the new diode bridge:

Field Diode Bridge

Feild Diode Bridge

9. Check that the leads are not grounded
and for clearance and tightness.

10. Replace the control panel and tighten the
6 sheet metal screws with the 5/16” nut
driver and 5/16” wrench.

11. Replace the top cover of the control box
and tighten the 8 sheet metal screws with
the 5/16” nut driver.

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Lead 200 and 200C are piggy-backed to the
positive (+) terminal. Depending on the bridge
used, this corner may be beveled and/or
marked with a + sign.

Lead 201 (Black) and 201B (Black) are piggy­backed on the negative (–) terminal, which will
always be located diagonally across from the
positive (+) terminal.

The Blue lead (7A) is attached to one AC ter­minal. Leads 9A and 9B are piggy-backed to
the other AC terminal.

8. Mount the field diode bridge using the
screw, washers and nut. Use the slot head
screwdriver and 11/32” wrench.

WELDANPOWER 125

F-45 F-45

TROUBLESHOOTING & REPAIR

IDLER PRINTED CIRCUIT BOARD REMOVAL

AND REPLACEMENT

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in accessing and removing the idler printed
circuit board for maintenance or replacement.

MATERIALS NEEDED

5/16" Nut driver
5/16" Wrench
1/4" Nut driver
Static grounding wrist strap

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WELDANPOWER 125

F-46 F-46

TROUBLESHOOTING & REPAIR

IDLER PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT (continued)

FIGURE F.19 - IDLER P.C. CIRCUIT BOARD

MOUNTING
SCREWS

J1J2

PROCEDURE

Before starting the following procedure, refer
to the topic "PC Board Troubleshooting
Procedures" at the beginning of this section.

1. Remove the engine spark plug wire to pre­vent accidental kickback or starting.

2. With the 5/16" nut driver, remove the 8
sheet metal screws that hold the top cover
in place. Remove the cover.

3. With the 5/16" nut driver and 5/16" wrench,
remove the 6 sheet metal screws that hold
the control panel in place. Carefully move
the control panel aside as far as the leads
will allow.

4. Locate and remove the two molex plugs
connected to the idler P.C. board. See
Figure F.19.

WP125 IDLER

M17578

MOUNTING
SCREW

CAUTION

Be sure to follow the recommended static-free
methods for handling printed circuit boards.
Failure to do so can result in permanent dam­age to the equipment.

6. Replace the old idler P.C. board. Mount the
new board with the 3 mounting screws and
1/4" nut driver.

7. Replace the control panel and tighten the 6
sheet metal screws with the 5/16" nut dri­ver and 5/16" wrench.

8. Replace the top cover of the control box
and tighten the 8 sheet metal screws with
the 5/16" nut driver.

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5. With the 1/4" nut driver, remove the 3 P.C.
board mounting screws.

6. Carefully remove the board.

WELDANPOWER 125

F-47 F-47

TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER BRIDGE REMOVAL

AND REPLACEMENT

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in removing the output rectifier bridge for
maintenance or replacement.

MATERIALS NEEDED

5/16" Nut driver
7/16" Wrench
3/8" Wrench
Dow Corning 340

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WELDANPOWER 125

F-48 F-48

TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued)

FIGURE F.20 - OUTPUT RECTIFIER CONNECTIONS

203

W2

W1

PROCEDURE

1. Remove the engine spark plug wire to pre­vent accidental kickback or starting.

2. With the 5/16" nut driver, remove the 8
sheet metal screws from the case top.

3. With the 7/16" wrench, remove the heavy
leads W1 and W2 from the stud terminals.
You do not have to remove the diode pig­tails from the terminals. See Figure F.20.

4. With the 7/16" wrench, remove the "N"
negative lead and the #204 lead from the
negative heat sink. Note placement of the
leads for reassembly.

5. With the 7/16" wrench, remove the choke
lead and the #203 lead from the positive
heat sink. Note placement of the leads for
reassembly.

6. With the 3/8" wrench, remove the four
mounting screws holding the output rectifi­er bridge assembly to the choke. Note the
placement of the insulators. When you
reassemble the output rectifier bridge, the
heat sink assembly MUST be electrically
isolated from case ground.

204

8. Reassembly: Refer to the Wiring Diagram
for proper connections to the positive and
negative sides of the rectifier assembly.
The two sides of the bridge are marked +
and –, respectively.

NOTE: Use Dow Corning 340 on all aluminum

electrical connection surfaces. If you
replace individual diodes, use Dow
Corning 340 on all mating surfaces
between the diodes and the heatsink.

9. Install the rectifier bridge assembly by tilt­ing it down into its position above the
choke assembly . Be sure that the positive
(+) side of the bridge, as marked, is on the
right side of the machine, looking from the
case front.

10. With the 3/8" wrench and slot head screw
driver, install the four mounting screws
(two on each side). Note the placement of
the nylon insulators. These must be in

place when you install the rectifier
bridge assembly in order to electrically
insulate the bridge from the choke lam­ination assembly.

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7. Carefully lift up and remove the output rec­tifier bridge assembly.

WELDANPOWER 125

F-49 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.

13. With the 7/16" wrench, install the heavy

leads W1 and W2 to the stud terminals.

14. Replace the top cover of the control box

and tighten the 8 sheet metal screws with
the 5/16" nut driver.

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WELDANPOWER 125

F-50 F-50

TROUBLESHOOTING & REPAIR

OUTPUT CHOKE REMOVAL AND REPLACEMENT

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in accessing and removing the output choke
assembly for maintenance or replacement.

MATERIALS NEEDED

5/16" Nut driver
5/16" Wrench
9/16" Wrench
1/2" Wrench
Diagonal cutters
Dow Corning 340

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WELDANPOWER 125

F-51 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 pre­vent accidental kickback or starting.

2. With the 5/16" nut driver, remove the 8
sheet metal screws from the case top.

3. With the 5/16" nut driver and 5/16" wrench,
remove the 6 sheet metal screws that hold
the control panel in place. Carefully move
the control panel aside as far as the leads
will allow.

4. Remove the output rectifier bridge. Refer
to "THE OUTPUT RECTIFIER BRIDGE
REMOVAL AND REPLACEMENT" proce­dure in this section of the manual.

5. With the 9/16" wrench, remove the heavy
choke lead from the positive output termi­nal.

6. With the 1/2" wrench, remove the four
mounting screws that hold the output
choke in place.

NOTE: The two thread forming screws (with

shake-proof lock washers) are used in
the two holes nearest the engine.

7. With the 5/16" nut driver, remove the one
sheet metal screw that holds the choke
assembly to the sheet metal.

8. Cut any necessary cable ties with the
diagonal cutters.

9. Unfasten any necessary cable restraints.

10. With the 5/16" nut driver, remove the
sheet metal grounding screw and the two
green ground wires.

11. Remove the two leads #208 and #209
from the idler solenoid.

12. Remove lead #14 from lead #14A by
pulling apart the quick connect splice.

13. Carefully remove the choke assembly by
lifting up and out.

NOTE: The idler solenoid will be removed

with the choke assembly . Take care to
slide the plunger out from the solenoid
housing.

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WELDANPOWER 125

F-52 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 sole­noid housing.

15. Assemble the quick connect splice that
connects lead #14 to lead #14A.

16. Connect the two leads #208 and #209 to
the idler solenoid.

17. With the 5/16" nut driver, install the sheet
metal grounding screw and the two green
ground wires.

18. With the 5/16" nut driver, install the one
sheet metal screw that holds the choke
assembly to the sheet metal.

19. With the 1/2" wrench, install the four
mounting screws that hold the output
choke in place.

NOTE: The two thread forming screws (with

shake-proof lock washers) are used in
the two holes nearest the engine.

20. With the 9/16" wrench, install the heavy
choke lead from the positive output termi­nal.

21. Replace the output rectifier bridge. Refer
to "THE OUTPUT RECTIFIER BRIDGE
REMOVAL AND REPLACEMENT" proce­dure in this section of the manual.

22. Replace any cable ties you cut for
removal. Fasten any cable restraints.

23. Replace the control panel and tighten the
6 sheet metal screws with the 5/16" nut
driver and 5/16" wrench.

24. Replace the top cover of the control box
and tighten the 8 sheet metal screws with
the 5/16" nut driver.

25. Start the gasoline engine and check the
low idle RPM. Low idle RPM should be
between 2250 - 2500 RPM. If adjustment
is necessary, refer to the topic "ENGINE
THROTTLE ADJUSTMENT TEST" in this
section of the manual.

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WELDANPOWER 125

F-53 F-53

TROUBLESHOOTING & REPAIR

STATOR/ROTOR REMOVAL AND REPLACEMENT

WARNING

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 elec­trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in removing the stator and/or rotor for main­tenance or replacement of either component.

MATERIALS NEEDED

Lincoln Electric Rotor Removal Kit (S20925) - FOR ROTOR REMOVAL ONLY

5/16" nut driver
1/2" socket wrench
6" socket extension
Slot head screw driver
5/8" socket wrench
7/16" socket wrench
7/16" open or box end wrench
9/16" open or box end wrench
3/4" socket or box end wrench
1/2" socket or box end wrench
Needle nose pliers
Diagonal cutters
Torque wrench (ft lbs)
Babbitt, leather, or wooden mallet
Volt/ohmmeter
12" (long) feeler gauge (.010)

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INSTRUCTIONS

For stator removal only, follow steps 1 -18 under STATOR REMOVAL PROCEDURE. For
reassembly of stator, go to REASSEMBLY PROCEDURE steps 3 - 23.

For rotor removal, follow the STATOR REMOVAL PROCEDURE, ROTOR REMOVAL PROCE­DURE, and REASSEMBLY PROCEDURE.

WELDANPOWER 125

F-54 F-54

TROUBLESHOOTING & REPAIR

STATOR/ROTOR REMOVAL AND REPLACEMENT(continued)

STATOR REMOVAL PROCEDURE

1. Remove the engine spark plug wire to pre­vent accidental kickback or starting.

2. Perform the Output Rectifier Bridge
Removal procedure.

3. Perform the Output Choke Removal proce­dure.

4. Remove lead #14A from the control box
assembly.

5. With the 5/16" nut driver, remove the 4
sheet metal screws that mount the control
box assembly to the stator frame.

6. Unplug the large 6 pin molex plug (quick
connect).

7. Cut any necessary cable ties.

8. Remove the W1 lead from the current
transformer.

9. Remove the green ground lead (GND-C)
from the wiring harness loom.

10. With the slot head screw driver, remove
leads #201A and 202B from the field
capacitor. It may be necessary to cut the
cable tie that holds the capacitor into its
mounting bracket.

11. Carefully slide out the control box assem­bly (with the control panel). Be careful to
clear the leads and the solenoid plunger
and throttle linkage.

12. Remove the brush holder assembly. Open
the brush holder assembly cover.
Squeeze the 2 tabs and depress the cover
at the top with a screw driver or your fin­gernail. The cover will drop open on its
bottom hinge. With the 1/4" nut driver,
remove the 2 screws that hold the brush
holder assembly in place. With the needle
nose pliers, gently remove the black and
the red wires. Set the brush holder aside.
Pull the wires up into the control box.

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WELDANPOWER 125

F-55 F-55

TROUBLESHOOTING & REPAIR

STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.22 - STATOR END BRACKET SUPPORT AND THRU-BOLTS

THRU­BOLTS

THRU-

BOLTS

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, remove the
2 nuts that hold the stator end bracket
support. See Figure F.22 for location.
There are 2 split-ring lock washers and 2
flat washers along with the nuts.

15. With the 7/16" socket and 7/16" end
wrench, remove the 4 thru-bolts for the
generator assembly. See Figure F.22. All
4 bolts have a split-ring lock washer
under the head and a shake-proof star
washer on the nut side. The bolts must
point toward the engine for reassembly.

NUTS

16. Lift up the stator and slide out the support
bracket. The engine will now rest on the
2 X 4.

17. With the babbitt/leather/wooden mallet,
tap off the end bracket. Alternate sides as
you tap; watch the bearing to judge the
amount of movement you're getting.

18. Once the end bracket is off, carefully pull
off the stator. IMPROPER HANDLING OF
THE STATOR CAN RESULT IN SHORTED
WINDINGS AND/OR LOST OUTPUT.

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WELDANPOWER 125

F-56 F-56

TROUBLESHOOTING & REPAIR

STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.23 - ROTOR WITH STATOR REMOVED

ROTOR

THRU-BOLT

ROTOR REMOVAL PROCEDURE

1. To remove the rotor, double check that the
spark plug wire is disconnected. You will
be turning the rotor during this procedure,
and this could accidentally cause engine
kickback.

2. With an impact wrench, remove the rotor
thru-bolt. See Figure F.23. If an impact
wrench is not available, use the 1/2" box
wrench. Hold the rotor with one hand and
shock the wrench with the mallet to
loosen the thru-bolt. The thru-bolt has a
star washer and lock washer, beveled to
conform to the rotor shaft. 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".

4. Tur ning it counterclockwise, screw in the
reverse thread bolt from the kit into the
rotor shaft until it bottoms out on the thru­bolt.

5. With an impact wrench, tighten the
reverse thread bolt until the rotor pops off
the engine crankshaft. If an impact
wrench is not available, use the 1/2" box
wrench. Hold the rotor with one hand and
shock the wrench with the mallet until the
rotor pops off the engine crankshaft.

6. Slide the rotor and blower (press-fitted to
the rotor) the rest of the way off the crank­shaft.

REASSEMBLY PROCEDURE

1. Lubricate the tapered engine crankshaft.
Slide the rotor onto the shaft.

2. Coat the rotor thru-bolt threads with
Lincoln E177-R retaining compound
(Locktite® 277). Place the beveled lock
washers onto the thru-bolt and insert it into
the rotor shaft. Hold the rotor and tighten
the thru-bolt to 22 - 25 ft lbs.

3. Carefully install the stator, with the leads at
the 1 o' clock position. IMPROPER HAN­DLING OF THE STATOR CAN RESULT IN
SHORTED WINDINGS AND/OR LOST
OUTPUT.

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WELDANPOWER 125

F-57 F-57

TROUBLESHOOTING & REPAIR

STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.24 - CHECKING ROTOR-STATOR AIR GAP

FEELER GAUGE

ROTOR

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 thru­bolts.

7. Tap the end bracket with the mallet as nec­essary to position it. Tighten the bolts to
22 - 25 ft lbs. Alternate tightening in order
to pull the assembly together evenly. As
you tighten, look through the brush hous­ing access door and watch the bearing to
judge end bracket movement and align­ment.

8. Check the rotor-stator air gap with the long
.010 feeler gauge. The measurement is
taken through the brush holder access
door; see Figure F.24. Turn the engine with
the recoil starter rope slightly so that the
rotor "iron" is up to take the measurement.
(The rotor has two flat sides, which are not
measured for air gap.) Slide in the gauge.
Then rotate the shaft 180 degrees and
measure again. If the gauge does not clear,
loosen the four end bracket thru-bolts,
reposition the end bracket, retighten the
bolts, and recheck the air gap. Repeat until
the proper .010 minimum air gap is
achieved (.030 maximum).

STATOR

9. Tighten the end bracket support nuts and
lock washers. Remove the 2 X 4 engine
support.

10. Reinstall the brush holder assembly.
Refer to the topic "BRUSH REMOVAL
AND REPLACEMENT" in this section of
the manual.

11. Slide the control box back into place.

12. Connect leads #201A and #202B to the
field capacitor. Replace the cable tie if it
was cut earlier.

13. Connect the green ground lead (GND-C)
to the wiring harness loom.

14. Connect the W1 lead to the current trans­former.

15. Connect the 6 pin molex plug.

16. With the 5/16" nut driver, install the con­trol box assembly to the stator frame with
4 sheet metal screws.

17. Connect lead #14A to its location inside
the control box assembly.

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WELDANPOWER 125

F-58 F-58

TROUBLESHOOTING & REPAIR

STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

18. Install the output choke. Refer to the
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.

20. Replace the control panel and tighten the
6 sheet metal screws.

22. Replace the top cover to the control box
and tighten the 8 sheet metal screws.

23. Conduct the "RETEST AFTER REPAIR"
procedure, the following topic in this sec­tion of the manual.

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WELDANPOWER 125

F-59 F-59

TROUBLESHOOTING & REPAIR

RETEST AFTER REPAIR

Retest a machine:

• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the
machine’s electrical characteristics.

OR

• If you repair or replace any electrical components.

ENGINE OUTPUT

No Load RPM Load RPM

Maximum Speed 3800 3500

Minimum Speed 3700 3300

WELDER/GENERATOR OUTPUT

1

Output Control Field Volts Field Amps Open Circuit Load Volts Load Amps

Volts RMS

Maximum 40 - 47 4.0 - 6.4 75 - 82 22 - 28 125 - 135

Minimum – – 70 - 78 23 - 27 40 - 55

AUXILIARY POWER RECEPTACLE OUTPUT

230 Volt Receptacle 115 Volt Receptacle

1

2

Output Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps

Control Volts Volts

Maximum 240 - 260 208 - 234 20.2 - 22.0 120 - 130 104 - 117 20.2 - 22.0

1

Current Control Dial set at MAXIMUM.

2

Output values of each receptacle can vary within the range shown but must be within 2 volts of each other.

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WELDANPOWER 125

NOTES

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WELDANPOWER 125

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

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WELDANPOWER 125

G-2 G-2

DIAGRAMS

WIRING DIAGRAM — (CODE 10158 & 10160)

PANEL

201B

GROUND

BRACKET

GREEN

GND-D

FRONT

BLK

(+)

OUTPUT STUDS

230 VOLT

J4

3B

BLK

3C

GREEN

GND-A

115 VOLT

WHITE TERMINALS

5A

ALL CASE FRONT

COMPONENTS SHOWN

VIEWED FROM REAR.

CLEVELAND, OHIO U.S.A.

MAG

MODULE

RUN/STOP

SWITCH

OIL LEVEL

D-RW

SWITCH

S21455

J3

NOTE:

GREEN

BLK

WHITE

GND-B

6B

6C

BLK

3C

3B

(15A CSA)

14A

CB2

(15A CSA)

20A

6A

6A

BLK

WHITE

BLK

5A

YEL

3A

SWITCH

CB1

BLUE

20A

BROWN

ENGINE WIRING

14

ELECTRICAL

SYMBOLS

PER E1537

6

5

3

1
2

4

15A

IDLE

AUTO

201C

9A

BLK

GROUND

GND-C

GREEN

6

5

3

7

15

9

HI

201A

(-)

BLK BLK

C1
600 FD

BRN

201

9B

D1

(-)

7A

201C

HOUR METER

SOLENOID

W2

STATOR

16

(+)

202

202A

(+)

+

200C

RED

RED

BLK

RED

CCW

R1

(-)

W1

BLK

CURRENT TRANS.

ROTOR

202B

WHITE

RED

200B

RED

3.3

100 W

200

RED

201B

(-)

204

BLK

BLK

200A

202A

WHITE

SOLENOID

IDLER

208

BRN

208

D2

9B

204

CHOKE

(+)

2

J2

1

5

14

1

BOARD

L1

203

AS SHOWN

16

IDLER P.C.

BRN

209

ORIENT WIRES

3A & 6A

34

RED

10

201B

209

J1

203

6

WIRING DIAGRAM - WELDANPOWER 125

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The

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specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

WELDANPOWER 125