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. (216) 481-8100
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
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