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IM530-C
®
Weldanpower 125 September, 2006
For use with Equipment having Code Numbers : 10158, 10160, 11183, 11406
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and
thoughtful operation on your part.
DO NOT INSTALL, OPERATE
OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR’S MANUAL
Copyright © 2006 Lincoln Global Inc.
� World's Leader in Welding and Cutting Products �
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause
cancer, birth defects, or other reproductive harm.
cancer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
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 Welding 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.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from localized Electric and Magnetic Fields (EMF). Welding
vaporizing on contact with hot engine parts current creates EMF fields around welding cables and
and igniting. Do not spill fuel when filling welding machines
tank. If fuel is spilled, wipe it up and do not
start engine until fumes have been 2.b. EMF fields may interfere with some pacemakers, and
eliminated.
welders having a pacemaker should consult their physician
____________________________________
before welding.
1.d. Keep all equipment safety guards, covers
and devices in position and in good
2.c. Exposure to EMF fields in welding may have other health
repair.Keep hands, hair, clothing and tools
effects which are now not known.
away from V-belts, gears, fans and all other
moving parts when starting, operating or
2.d. All welders should use the following procedures in order to
repairing equipment.
minimize exposure to EMF fields from the welding circuit:
____________________________________________________
2.d.1. Route the electrode and work cables together - Secure
1.e. In some cases it may be necessary to remove safety
them with tape when possible.
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.2. Never coil the electrode lead around your body.
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
2.d.3. Do not place your body between the electrode and
parts.
work cables. If the electrode cable is on your right
___________________________________________________
side, the work cable should also be on your right side.
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. 2.d.4. Connect the work cable to the workpiece as close as
___________________________________________________ possible to the area being welded.
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance 2.d.5. Do not work next to welding power source.
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
Mar �95
ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
kill. 4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on.
open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare
should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
FUMES AND GASES
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and 5. b. The operation of welding fume control equipment is affected
welding machine in good, safe operating condition. Replace by various factors including proper use and positioning of
damaged insulation. the equipment, maintenance of the equipment and the
specific welding procedure and application involved.
3.g. Never dip the electrode in water for cooling. Worker exposure level should be checked upon installation
and periodically thereafter to be certain it is within
3.h. Never simultaneously touch electrically “hot� parts of applicable OSHA PEL and ACGIH TLV limits.
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
of both welders. coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.i. When working above floor level, use a safety belt to protect form phosgene, a highly toxic gas, and other irritating
yourself from a fall should you get a shock. products.
3.j. Also see Items 6.c. and 8. 5.d. 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.e. 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.
5.f. Also see item 1.b.
AUG 06
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate
8.b. Install equipment in accordance with the U.S. National
circuits. This can create fire hazards or overheat lifting
Electrical Code, all local codes and the manufacturer’s
chains or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Pour votre propre protection lire et observer toutes les
instructions et les précautions de sûreté specifiques qui
6. Eloigner les matériaux inflammables ou les recouvrir afin de
parraissent dans ce manuel aussi bien que les précautions de
prévenir tout risque d’incendie dû aux étincelles.
sûreté générales suivantes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
Sûreté Pour Soudage A L’Arc
la masse. Un court-circuit accidental peut provoquer un
1. Protegez-vous contre la secousse électrique:
échauffement et un risque d’incendie.
a. Les circuits à l’électrode et à la piéce sont sous tension
8. S’assurer que la masse est connectée le plus prés possible
quand la machine à souder est en marche. Eviter toujours
de la zone de travail qu’il est pratique de le faire. Si on place
tout contact entre les parties sous tension et la peau nue
la masse sur la charpente de la construction ou d’autres
ou les vétements mouillés. Porter des gants secs et sans
endroits éloignés de la zone de travail, on augmente le risque
trous pour isoler les mains.
de voir passer le courant de soudage par les chaines de
b. Faire trés attention de bien s’isoler de la masse quand on
levage, câbles de grue, ou autres circuits. Cela peut
soude dans des endroits humides, ou sur un plancher
provoquer des risques d’incendie ou d’echauffement des
metallique ou des grilles metalliques, principalement dans
chaines et des câbles jusqu’� ce qu’ils se rompent.
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
9. Assurer une ventilation suffisante dans la zone de soudage.
masse.
Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble
galvanisées plombées, ou cadmiées ou tout autre métal qui
de soudage et la machine à souder en bon et sûr état
produit des fumeés toxiques.
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir.
d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension
chaleur ou les rayons de l’arc peuvent réagir avec les
des porte-électrodes connectés à deux machines Ã
vapeurs du solvant pour produire du phosgéne (gas
souder parce que la tension entre les deux pinces peut
fortement toxique) ou autres produits irritants.
être le total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
11. Pour obtenir de plus amples renseignements sur la sûreté,
courant pour soudage semi-automatique, ces precautions
voir le code “Code for safety in welding and cutting� CSA
pour le porte-électrode s’applicuent aussi au pistolet de
Standard W 117.2-1974.
soudage.
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
PRÉCAUTIONS DE SÛRETÉ POUR
quelle partie du corps.
LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
TRANSFORMATEUR ET À
donc:
REDRESSEUR
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 1. Relier à la terre le chassis du poste conformement au code
ou quand on regarde l’arc. de l’électricité et aux recommendations du fabricant. Le
b. Porter des vêtements convenables afin de protéger la dispositif de montage ou la piece à souder doit être branché
peau de soudeur et des aides contre le rayonnement de à une bonne mise à la terre.
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au 2. Autant que possible, I’installation et l’entretien du poste
soudage à l’aide d’écrans appropriés et non- seront effectués par un électricien qualifié.
inflammables.
3. Avant de faires des travaux à l’interieur de poste, la
4. Des gouttes de laitier en fusion sont émises de l’arc de debrancher à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse, 4. Garder tous les couvercles et dispositifs de sûreté à leur
pantalons sans revers, et chaussures montantes. place.
Mar. �93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
� For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
� For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links� and then
“Product Registration�. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi vi
TABLE OF CONTENTS
Page
Safety .....................................................................................................................i-iv
Installation..................................................................................................................1-7
Technical Specifications ............................................................................................1
Input - Gasoline Engine
Rated Output - Welder
Output - Welder and Generator
Physical Dimensions
Location and Ventilation.............................................................................................2
Storing........................................................................................................................2
Stacking .....................................................................................................................3
Tilting .........................................................................................................................3
Lifting .........................................................................................................................3
Pre-Operation Engine Service ...................................................................................3
Electrical Output Connections.....................................................................................4
Machine Grounding.....................................................................................................5
Plugs and Hand Held Equipment................................................................................6
Auxiliary Power Receptacles ......................................................................................6
Premises Wiring..........................................................................................................6
Circuit Breakers ..........................................................................................................6
Electrical Device use with the Weldanpower 125.......................................................7
Operation..................................................................................................................9-17
Safety Instructions .....................................................................................................9
Graphic Symbols......................................................................................................10
Product Description..................................................................................................11
Recommended Applications ....................................................................................11
Operational Features and Controls..........................................................................11
Design Features and Advantages............................................................................11
Welding Capability ...................................................................................................11
Limitations................................................................................................................11
Controls and Settings...............................................................................................12
Engine Operation................................................................................................13-14
Welding Operation ..............................................................................................14-15
Generator Operation ................................................................................................15
Electrode Selection Guide .......................................................................................16
Generator Power Applications .................................................................................17
Accessories.................................................................................................................18
Maintenance ...........................................................................................................19-20
Safety Precautions...................................................................................................19
Routine and Periodic Maintenance.....................................................................19-20
Troubleshooting ....................................................................................................21-24
How To Use Troubleshooting Guide........................................................................21
Troubleshooting Guide .......................................................................................22-24
Wiring Diagram .....................................................................................................25, 26
Dimension Print ..........................................................................................................27
Parts Manual ..............................................................................................P-256 Series
WELDANPOWER 125
INSTALLATION
TECHNICAL SPECIFICATIONS - WELDANPOWER 125
INPUT - GASOLINE ENGINE
Speed Displacement
Description Ignition Capacities
Manufacturer
(Automatic Electronic
Idler) 18.06 cu. in. Manual, Recoil Fuel: 1.6 gal. (6.1 l)
1 cylinder,
Briggs &
(296 cc)
4 cycle start;
Stratton
3400 RPM Full Load
air-cooled Oil: 1 1/4 qts. (1.2 l)
Vanguard®
Bore & Stroke Manual choke
gasoline driven
Model 185432
3750 RPM High Idle
9 HP @
Two Year
3.15x 2.33 in.
3600 RPM Lifetime
Warranty
Aluminum Block /w 2400 RPM Low Idle (80 x 59 mm) ignition
Codes
Cast Iron Sleeve warranty
(10158, 10160)
Displacement
1 cylinder,
4 cycle
16.17 cu. in.
air-cooled
Robin / Subaru
(265 cc)
3400 RPM Full Load
OHC gasoline Manual, Recoil Fuel: 1.6 gal. (6.1 l)
9 HP @ start;
EX 27
Bore & Stroke
3750 RPM High Idle
3600 RPM Oil: 1 .1 qts. (1.0 l)
Aluminum Block /w Manual choke
Codes
2.95x 2.36 in.
Cast Iron Sleeve
(11183, 11406)
(75 x 60 mm)
RATED OUTPUT - WELDER
Duty Cycle Amps Volts at Rated Amperes
125 amps DC Constant Current
30%
25 VDC
100 amps DC Constant Current
60%
OUTPUT - WELDER AND GENERATOR
Welding Ranges AC Auxiliary Power
Welder Open Circuit Voltage
4500 Watts 115/230V 1PH
100 % Duty Cycle
(Codes 10158, 10160)
50 - 125 Amps DC 80 VDC Max.
5500 Surge Watts
4250 Continuous Watts
120 / 240 V 1PH
(Codes 11183, 11406)
PHYSICAL DIMENSIONS
Weight
Depth
Width
Height
Codes 10158, 10160
190 lbs
(86.4kg)
30.0 in.
20.0 in.
21.13 in.
(Codes 11183, 11406)
762 mm
508 mm
530 mm
180 lbs
(81.7 kg)
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
0° F TO 104° F (-18° C TO 40° C) -40° F TO 131° F (-40° C TO 55° C)
WELDANPOWER 125 �1�
INSTALLATION
LOCATION AND VENTILATION
Read this entire installation section before you
start installation.
Whenever you use the Weldanpower® 125, be sure
that clean cooling air can flow around the machine’s
gasoline engine and the generator. Avoid dusty, dirty
Safety Precautions
areas. Also, keep the machine away from heat
sources. Do not place the back end of the generator
WARNING anywhere near hot engine exhaust from another
machine. And of course, make sure that engine
Do not attempt to use this equipment until you
exhaust is ventilated to an open, outside area.
have thoroughly read all operating and
maintenance manuals supplied with your The Weldanpower 125 must be used outdoors. Do not
set the machine in puddles or otherwise submerge it
machine. They include important safety
in water. Such practices pose safety hazards and
precautions, detailed engine starting, operating
cause improper operation and corrosion of parts.
and maintenance instructions, and parts lists.
Always operate the Weldanpower 125 with the case
roof on and all machine components completely
assembled. This will help to protect you from the
Hazards of Electric Shock, Engine dangers of moving parts, hot metal surfaces, and live
Exhaust & Moving Parts electrical devices.
STORING
WARNING
1. Store the machine in a cool, dry place when it is
not in use. Protect it from dust and dirt. Keep it
ELECTRIC SHOCK can kill.
where it can not be accidentally damaged from
� Do not touch electrically live parts
construction activities, moving vehicles and other
or electrode with skin or wet
hazards.
clothing.
2. If you will be storing the machine for over 30
� Insulate yourself from work and
days, you should drain the fuel to protect fuel
ground.
system and carburetor parts from gum deposits.
� Always wear dry insulating gloves.
Empty all fuel from the tank and run the engine
until it stops from lack of fuel.
(For Codes 10158, 10160)
ENGINE EXHAUST can kill. 3. You can store the machine for up to 24 months if
you use Briggs & Stratton Gasoline Additive, Part
� Use in open, well ventilated areas
or vent exhaust outside. No. 5041 (available from any Authorized Briggs &
Stratton Service Center), in the fuel system. Mix
� Do not stack anything on or near
the additive with the fuel in the tank and run the
the engine.
engine for a short time to circulate the additive
through the carburetor.
(For Codes 11183, 11406)
MOVING PARTS can injure.
3a. You can store the machine for up to 24 months if
� Do not operate with doors open or
you use a stabilizing Additive in the fuel system.
guards off.
Mix the additive with the fuel in the tank and run
� Stop engine before servicing.
the engine for a short time to circulate the additive
� Keep away from moving parts. through the carburetor.
4. While the engine is still warm, drain the oil and
Only qualified personnel should install, use, or refill with fresh 10W30 oil.
service this equipment. 5. Remove the spark plug and pour approximately
1/2 ounce (15ml) 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.
WELDANPOWER 125
�2�
INSTALLATION
Oil
STACKING
The Weldanpower 125 is shipped with the engine
Weldanpower 125 machines CANNOT be stacked.
filled with SAE 10W30 oil. CHECK THE OIL LEVEL
BEFORE YOU START THE ENGINE. This is an
TILTING added precaution. Do not screw in dipstick when
checking oil level. DO NOT OVERFILL. Be sure the
Place the machine on a secure, level surface fill plug is tight after servicing.
whenever you use it or store it. Any surfaces you
place it on other than the ground must be firm, non- Fuel
skid, and structurally sound.
Fill the fuel tank with clean, fresh, regular grade
The gasoline engine is designed to run in a level (minimum 85 octane for codes 10158, 10160 and 87
position for best performance. It can operate at an octane for codes 11183, 11406) lead free gasoline.
angle, but this should never be more than 15 degrees DO NOT MIX OIL WITH GAS. The Weldanpower 125
in any direction. If you do operate it at a slight angle, capacity is approximately 1.6 gallons (6.1 Liter). DO
be sure to check the oil regularly and keep the oil NOT OVERFILL, allow room in the fuel tank for fuel
level full. Also, fuel capacity will be a little less at an expansion.
angle.
Spark Arrester
LIFTING
(For Codes 10158, 10160)
Some federal, state or local laws may require
The Weldanpower 125 should be lifted by two people.
(See Specification section for weight). Its welded tube gasoline engines to be equipped with exhaust spark
roll cage is designed to make lifting easier. arresters when they are operated in certain locations
where unarrested sparks may present a fire hazard.
PRE-OPERATION ENGINE SERVICE
The standard mufflers & deflectors included with this
Read and understand the engine operating and machine do not qualify as spark arresters. When
required by local regulations, a suitable spark arrester
maintenance instructions supplied with this machine
(available from Briggs & Stratton) must be installed
before you operate the Weldanpower 125.
and properly maintained.
WARNING
(For Code 11183, 11406)
� Keep hands away from muffler or HOT engine
Some federal, state or local laws may require
parts.
gasoline engines to be equipped with exhaust spark
� Stop the engine when fueling. arresters when they are operated in certain locations
where unarrested sparks may present a fire hazard.
� Do not smoke when fueling.
The standard muffler included with this machine does
� Remove fuel cap slowly to release pressure.
qualify as a spark arrester.
� Do not overfill tank.
CAUTION
� Wipe up spilled fuel and allow fumes to clear
before starting engine. An incorrect additional arrester may lead to
damage to the engine or adversely affect
� Keep sparks and flame away from tank.
performance.
-----------------------------------------------------------------------
WELDANPOWER 125 �3�
INSTALLATION
FIGURE A.1 and A.1a - WELDANPOWER 125 OUTPUT CONNECTIONS
FIGURE A.1a
FIGURE A.1
1 1
HOURS
50 HOURS
AMPS 50
AMPS
75
75
AMPS
AMPS
MAX
100 MAX
100
AMPS
AMPS
IDLER
125
125
AMPS
AMPS
6 6
WARNING
WELDANPOWER 125 WARNING
WELDANPOWER 125
ELECTRODE SELECTION GUIDE ELECTRODE SELECTION GUIDE
+ +
- -
5 5
3 3
4 4
2 2
(For Codes 10158, 10160) (For Code 11183, 11406)
1. CURRENT CONTROL DIAL 1. CURRENT CONTROL DIAL
2. WELD OUTPUT TERMINALS (2) 2. WELD OUTPUT TERMINALS (2)
3. GROUND STUD 3. GROUND STUD
4. CIRCUIT BREAKERS (2) - 20 AMP 4. CIRCUIT BREAKERS (2) - 20 AMP
5. RECEPTACLE - 230 VOLT, 20 AMP 5. RECEPTACLE - 240 VOLT, 20 AMP
6. DUPLEX RECEPTACLE - 115 VOLT, 20 AMP 6. DUPLEX RECEPTACLE - 120 VOLT, 20 AMP
ELECTRICAL OUTPUT CONNECTIONS
(For Codes 10158, 10160) TABLE A.1
See Figure A.1 for the location of the current control
RECOMMENDED WELDING CABLE
dial, weld output terminals, ground stud, circuit
SIZE AND LENGTH
breakers, 230 and 115 volt receptacles.
TOTAL COMBINED LENGTH OF
(For Code 11183, 11406)
ELECTRODE AND WORK CABLES
See Figure A.1a for the location of the current control
dial, weld output terminals, ground stud, circuit Cable 125 Amps
breakers, 240 and 120 volt receptacles. Length 30% Duty Cycle
WELDING CABLE CONNECTIONS 0-50 ft (0-15m) 6 AWG
Cable Size and Length 50-100 ft (15-30 m) 5 AWG
Be sure to use welding cables that are large enough. 100-150 ft (30-46 m) 3 AWG
The correct size and length becomes especially
important when you are welding at a distance from the 150-200 ft (46-61 m) 2 AWG
welder.
200-250 ft (61-76m) 1 AWG
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.
WELDANPOWER 125
�4�
INSTALLATION
Cable Installation MACHINE GROUNDING
Install the welding cables to your Weldanpower 125 Because this portable engine driven welder or
as follows. See Figure A.1 for the location of parts. generator creates its own power, it is not necessary to
connect its frame to an earth ground, unless the
1. The gasoline engine must be OFF to install machine is connected to premises wiring (your home,
welding cables. shop, etc.).
2. Remove the 1/2-13 flanged nuts from the output To prevent dangerous electric shock, other equipment
terminals. to which this engine driven welder supplies power,
must:
3. Connect the electrode holder and work cables to a) be grounded to the frame of the welder using a
the weld output terminals. Normally, the electrode grounded type plug
cable is connected to the positive (+) output stud. or
b) be double insulated
4. Tighten the flanged nuts securely.
When this welder is mounted on a truck or trailer, the
5. Be certain that the metal piece you are welding machine grounding stud must be securely
(the “work�) is securely connected to the work connected to the metal frame of the vehicle.
clamp and cable.
Where this engine driven welder is connected to
6. Check and tighten the connections periodically. premises wiring such as that in your home or shop, its
frame must be connected to the system earth ground.
CAUTION See further connection instructions in the section
entitled Standby Power Connections as well as the
article on grounding in the latest U.S. National
� Loose connections will cause the output studs to
Electrical Code and your local code.
overheat and and the studs may eventually melt.
In general if the machine is to be grounded, it should
� Do not cross welding cables at output stud
be connected with a #8 or larger copper wire to a solid
connection. Keep isolated and separate from one
earth ground such as a metal water pipe going into
another. the ground for at least ten feet and having no
insulated joints, or to the metal framework of a
------------------------------------------------------------------------
building which has been effectively grounded. The
Lincoln Electric offers a welding accessory kit with #6 U.S. National Electrical Code lists a number of
welding cables. See the ACCESSORIES section of alternate means of grounding electrical equipment. A
this manual for more information. machine grounding stud marked with the symbol
is provided on the front of the welder.
For more information on welding , see WELDING
OPERATION in the OPERATION section of this
WARNING
manual.
DO NOT GROUND MACHINE TO A PIPE WHICH
CARRIES EXPLOSIVE OR COMBUSTIBLE
MATERIAL.
WELDANPOWER 125 �5�
INSTALLATION
PLUGS AND HAND HELD EQUIPMENT PREMISES WIRING
For further protection against electric shock, any The Weldanpower 125 three-wire, grounded neutral
electrical equipment connected to the generator generator allows it to be connected to premises
receptacles must use a three-blade, grounded type wiring.
plug or an Underwriter’s Laboratories (UL) approved
double insulated tool with a two blade plug.
WARNING
WARNING Only a licensed, certified, trained electrician should
install the machine to a premises or residential
Never operate this machine with damaged or electrical system. Be certain that:
defective cords. All electrical equipment must be in
safe operating condition. � The premises is isolated and no back feeding 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.
AUXILIARY POWER RECEPTACLES
Check your state and local requirements.
The control panel of the Weldanpower 125 features
� A double pole, double throw transfer switch in
two auxiliary power receptacles:
conjunction with the properly rated double throw
circuit breaker is connected between the
(For Codes 10158, 10160)
generator power and the utility meter.
� A 20 amp (15 amp CSA), 115 volt duplex (double
------------------------------------------------------------------------
outlet) receptacle.
The Weldanpower 125 does not have a combined
120/240 volt receptacle and cannot be connected to a
� A 20 amp (15 amp CSA), 230 volt single outlet
premises as described in other Lincoln literature.
receptacle.
Remember that the Weldanpower 125 is intended
See Figure A.1
only for backup, intermittent use. It cannot withstand
long-term use without proper maintenance. See the
Through these receptacles the machine can supply up
MAINTENANCE section of this manual for more
to 4,500 watts (3,500 watts CSA) of single-phase 60
information.
Hertz AC power. The machine output voltages meet
UL standards and fall within ± 10% of the rated
voltage.
CIRCUIT BREAKERS
(For Codes 11183, 11406) Auxiliary power is protected by circuit breakers. When
� A 20 amp,120 volt duplex (double outlet) the machine is operated in high temperature
receptacle. environments, the breakers may tend to trip at lower
loads than normally.
� A 20 amp, 240 volt single outlet receptacle.
CAUTION
See Figure A.1a
NEVER BYPASS THE CIRCUIT BREAKERS.
Through these receptacles the machine can supply up
WITHOUT OVERLOAD PROTECTION, THE UNIT
to 5,500 watts surge or 4250 watts continuous of
COULD OVERHEAT AND/OR CAUSE DAMAGE TO
single-phase 60 Hertz AC power. The machine output
voltages meet UL standards and fall within ± 10% of THE EQUIPMENT BEING USED.
the rated voltage.
------------------------------------------------------------------------
WELDANPOWER 125
�6�
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 recom-
mended 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 OPERA-
TION 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 a Weldanpower 125.
WELDANPOWER 125 �7�
NOTES
WELDANPOWER 125
�8�
OPERATION
OPERATING INSTRUCTIONS
General Warnings
SAFETY INSTRUCTIONS
WARNING WARNING
ELECTRIC SHOCK ENGINE EXHAUST can kill.
can kill.
� Use in open, well ventilated areas
or vent exhaust outside.
� Do not touch electrically live parts
� Do not stack anything on or near
or electrode with skin or wet
the engine.
clothing.
� Insulate yourself from work and
MOVING PARTS can injure.
ground.
� Do not operate with doors open or
guards off.
� Always wear dry insulating
gloves. � Stop engine before servicing.
� Keep away from moving parts.
FUMES AND GASES
Only qualified personnel should install, use, or
can be dangerous.
service this equipment.
� Keep your head out of fumes.
Observe additional Safety Guidelines detailed
throughout this manual.
� 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.
ARC RAYS
can burn.
� Wear eye, ear and body
protection.
WELDANPOWER 125 �9�
OPERATION
GRAPHIC SYMBOLS USED ON THIS EQUIPMENT OR IN THIS MANUAL
WARNING / CHOKE
CAUTION
AIR CLEANER
OIL
CIRCUIT
FUEL BREAKER
WORK CLAMP
GROUND
(AUXILIARY
POWER)
For Codes 10158, 10160 only.
ELECTRODE
FAST WELDING ARC
SLOW
WELDANPOWER 125
� 10 �
OPERATION
PRODUCT DESCRIPTION DESIGN FEATURES AND ADVANTAGES
The Weldanpower 125 is designed for commercial use welder / � 125 amp DC constant current welding for stick
generator applications. As a welder it provides 125 amps of DC electrodes.
constant current for welding with DC stick electrodes. A single � Lightweight / portable.
dial lets you select a full range of welding output from 50 to 125 � Full range, continuous welding output control with a
amps. single knob.
� Automatic shutdown under low oil level condition.
(For Codes 10158, 10160) � Hour Meter Standard.
As a generator it can supply up to 4500 continuous watts of 115
/ 230 volt, single-phase AC power. The machine is portable. (For Codes 10158, 10160)
� 4500 Watts of continuous 115 / 230 volt single phase
A Briggs & Stratton 9 HP Vanguard air cooled, OHV gasoline AC auxiliary power (3500 Watts CSA).
engine powers the welder / generator. It has an engine � Briggs & Stratton 9 HP Vanguard overhead valve air-
warranty of 2 years and a lifetime warranty on the engine cooled gasoline engine. Smooth running, long life.
ignition system.
(For Codes 11183, 11406)
� 5500 Surge watts or 4250 Watts of continuous 120 /
(For Codes 11183, 11406) 240 volt single phase AC auxiliary power.
As a generator it can supply up to 5500 surge watts or 4250 � Robin / Subaru 9 HP EX 27 overhead cam air-cooled
continuous watts of 120 / 240 volt, single-phase AC power. The gasoline engine. Smooth running, long life.
machine is portable.
WELDING CAPABILITY
A Robin / Subaru 9 HP EX 27 air cooled, OHC gasoline engine
The Weldanpower 125 is rated 125 amps, 25 VDC at 30%
powers the welder / generator. It has an engine warranty of 3
duty cycle on a ten-minute basis. This means that you can
years.
load the welder to 125 amps for three minutes out of every
ten-minute period. The machine is capable of higher duty
RECOMMENDED APPLICATIONS
cycles at lower output currents. For example, you can load
the welder to 100 amps for six minutes out of ten for a 60%
Welder duty cycle.
The Weldanpower 125 provides excellent constant current DC
The current is continuously variable from 50 to 125 amps
welding output for stick (SMAW) welding.
DC. The Weldanpower 125 can, therefore, weld with all
3/32 and most 1/8 inch diameter Lincoln DC electrodes.
Generator
The Weldanpower 125 gives smooth AC generator output for
continuous auxiliary power usage within the engine
LIMITATIONS
manufacturer’s required maintenance recommendations.
� The Weldanpower 125 is not recommended for any
processes besides those that are normally performed
OPERATIONAL FEATURES AND using stick welding (SMAW) procedures.
CONTROLS � The Weldanpower 125 is not recommended for pipe
thawing.
The Weldanpower 125 was designed for simplicity. Therefore, it
� During welding, generator power is limited to 100 watts,
has very few operating controls. A single dial on the control
and output voltages can drop from 120 to 80 volts and
panel lets you select either welder or generator use. For
240 to 160 volts. Therefore, DO NOT OPERATE ANY
welding, the same dial selects continuous current output over
SENSITIVE ELECTRICAL EQUIPMENT WHILE YOU ARE
the machine’s 50 to 125 amp range.
WELDING.
The gasoline engine controls include a recoil starter, choke and
stop switch. See ENGINE OPERATION in the OPERATION
section of this manual for details about starting, running,
stopping,and breaking in the gasoline engine.
WELDANPOWER 125 � 11 �
OPERATION
CONTROLS AND SETTINGS Output Control Panel. Gasoline engine controls are
mounted on the engine. See Figure B.1, B.1a and the
All welder/generator controls are located on the figures in the engine operation section.
FIGURE B.1 and B.1a � OUTPUT PANEL CONTROLS
FIGURE B.1a
FIGURE B.1 9
9
1
1
10
HOURS
HOURS
50
50 AMPS
AMPS
75
75
AMPS
AMPS
MAX
MAX
100
100
AMPS
AMPS
IDLER
125
125
AMPS
AMPS
8
8 WARNING
WARNING WELDANPOWER 125
WELDANPOWER 125
ELECTRODE SELECTION GUIDE
ELECTRODE SELECTION GUIDE
+
+ -
- 2
2 7
7
5
5
5 5
3
3 4 4
6 6
(For Codes 11183, 11406)
(For Codes 10158, 10160)
1. CURRENT CONTROL DIAL
1. CURRENT CONTROL DIAL
2. ELECTRODE SELECTION GUIDE
2. ELECTRODE SELECTION GUIDE
3. WELD POSITIVE OUTPUT TERMINAL
3. WELD POSITIVE OUTPUT TERMINAL
4. WELD NEGATIVE OUTPUT TERMINAL
4. WELD NEGATIVE OUTPUT TERMINAL
5. GROUND STUD
5. GROUND STUD
6. 20 AMP CIRCUIT BREAKERS (2)
6. 20 AMP CIRCUIT BREAKERS (2)
7. 20 AMP, 240 VOLT RECEPTACLE
7. 20 AMP, 230 VOLT RECEPTACLE
8. 20 AMP, 1120 VOLT DUPLEX RECEPTACLE
8. 20 AMP, 115 VOLT DUPLEX RECEPTACLE
9. HOUR METER
9. HOUR METER
10. IDLER SWITCH
(For Codes 10158, 10160)
WELDER/GENERATOR CONTROLS
6. CIRCUIT BREAKERS (2): Provide separate
See Figure B.1 and B.1a for the location of the following overload current protection for the 115 volt and
features: 230 volt receptacles.
7. 230 VOLT RECEPTACLE: Connection point for
1. CURRENT CONTROL DIAL: Adjusts continuous
supplying 230 volt power to operate one
current output. The amperages on the dial correspond
electrical device.
to the approximate amperages needed for specific
8. 115 VOLT DUPLEX RECEPTACLE: Connection
Lincoln welding electrodes.
point for supplying 115 volt power to operate one
2. ELECTRODE SELECTION GUIDE: Provides or two electrical devices.
recommended electrode type, size, and welder output 9. HOUR METER: Records the time that the engine
setting based on the thickness of the work. has run for maintenance purposes.
10. IDLER SWITCH: Allows for setting the idle speed
3. WELD POSITIVE OUTPUT TERMINAL Provides the
of the engine for FAST IDLE or AUTOMATIC
connection point for either the electrode holder or the
IDLE.
work cable. (Because the Weldanpower 125 is a DC
output machine, either output terminal can be used for
(For Codes 11183, 11406)
either cable.)
6. CIRCUIT BREAKERS (2): Provide separate overload
4. WELD NEGATIVE OUTPUT TERMINAL Provides the current protection for the 120 volt and 240 volt
connection point for either the electrode holder or the receptacles.
work cable. (Because the Weldanpower 125 is a DC 7. 240 VOLT RECEPTACLE: Connection point for
output machine, either output terminal can be used for supplying 240 volt power to operate one electrical
either cable.) device.
8. 120 VOLT DUPLEX RECEPTACLE: Connection point
5. GROUND STUD: Provides a connection point for
for supplying 120 volt power to operate one or two
connecting the machine case to earth ground for the
electrical devices.
safest grounding procedure.
9. HOUR METER: Records the time that the engine has
run for maintenance purposes.
WELDANPOWER 125
� 12 �
OPERATION
Next, move the choke control lever on the engine to
ENGINE OPERATION
the “Chock� position.
Engine Control Function/Operation Note: For a hot engine leave the chock control lever in
the “Run� position.
Rocker “Run/Stop� Switch (For Codes 10158,
10160 Only)
(For Codes 10158, 10160)
The two position “Run/Stop� switch is marked “I� and Set the “Idler Control� switch to the automatic position.
“O� on the red rocker and is located on the rear of the Place the “Run/Stop� switch on the engine in the run
engine. In the run (I) position, the engine ignition (I) position. To start, pull the starter cord slowly until
circuit is energized, and the engine can be started by resistance is felt, then pull the cord rapidly. Slowly
pulling the recoil rope starter. In the stop (O) position, move the choke control to the “Run� position (opening
the electronic ignition is grounded, and the engine the choke) immediately after the engine has started.
shuts down. The engine will go to low idle speed after
approximately 12 seconds. Allow the engine to warm
“ON/OFF� Switch (For Codes 11183, 11406) up gradually by letting it run at low idle for a few
minutes.
A two position switch located on the rear of the
engine. In the “ON�(I) position, the engine ignition
(For Codes 11183, 11406)
circuit is energized and the engine can be started by
Place the “On/Off� switch on the engine in the run (I)
pulling the recoil rope starter. In the “OFF�(O)
position. To start, pull the starter cord slowly until
position, the electronic ignition is grounded and the
resistance is felt, then pull the cord rapidly. Slowly
engine shuts down.
move the choke control to the “Run� position (opening
the choke) immediately after the engine has started.
“Idler Control� Switch (For Codes 10158, 10160 Allow the engine to warm up gradually by letting it run
only) at low idle for a few minutes.
The “idler switch� is located at the upper left of the Stopping the Engine
control panel.
The switch has two positions: Remove all welding and auxiliary power loads and
allow engine to run for a few minutes to cool the
1. In the “high idle� position ( ), the idler is off engine.
and the engine runs at the high idle speed
controlled by the governor. (For Codes 10158, 10160)
Stop the engine by placing the rocker “Run/Stop�
2. In the “automatic idle� position ( / ) the switch in the “Stop� (O) position.
idler operates as follows:
(For Codes 11183, 11406)
a. When welding or drawing auxiliary power Stop the engine by placing the “On/Off� switch in the
(approximately 100 watts or higher) from the “Off� (O) position. Close the fuel shut off valve.
receptacles, the engine operates at full speed.
WARNING
b. When welding ceases or the power load is
turned off, the engine will remain at high idle for
approximately 12 seconds before automatically Close the fuel valve when the machine is
shifting to low idle. transported to prevent fuel leakage from
the carburetor.
c. When the welding load or power load is ------------------------------------------------------------------------
reapplied, the engine will automatically return to
high idle speed without delay.
Starting/Shutdown Instructions
Be sure all Pre-Operation Engine Service has been
performed. (See INSTALLATION section)
Remove all loads connected to the AC power
receptacles. Before starting, first open the fuel shutoff
valve.
WELDANPOWER 125 � 13 �
OPERATION
WELDING OPERATION
Break-in Period
GENERAL INFORMATION
It is normal for any engine to use larger quantities of
oil until break-in is accomplished. Check the oil level
WARNING
twice a day during the break-in period (about 50
running hours). Change the oil after the first 5 hours
ELECTRIC SHOCK can kill.
of operation. See the Engine Instruction Manual for
further details. � Do not touch electrically live parts
or electrode with skin or wet
clothing.
CAUTION � Insulate yourself from work and
IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE ground.
UNIT SHOULD BE SUBJECTED TO MODERATE � Always wear dry insulating gloves.
LOADS, WITHIN THE RATING OF THE MACHINE.
AVOID LONG IDLE RUNNING PERIODS. REMOVE
LOADS AND ALLOW ENGINE TO COOL SEVERAL
ENGINE EXHAUST can kill.
MINUTES AT LOW IDLE BEFORE SHUTDOWN.
� Use in open, well ventilated areas
-----------------------------------------------------------------------
or vent exhaust outside.
� Do not stack anything on or near
Low Oil Sensing
the engine.
This engine has a built in sensor which responds to
low oil level (not pressure). When activated, the
MOVING PARTS can injure.
system will shut the engine down. The engine will not
� Do not operate with doors open or
restart until sufficient oil is added. Check oil level
guards off.
frequently and add oil as required to the full mark on
� Stop engine before servicing.
the dipstick. DO NOT OVERFILL.
� Keep away from moving parts.
Typical Fuel Consumption
(For Codes 10158, 10160) Only qualified personnel should install, use, or
service this equipment.
BRIGGS& STRATTON
The Weldanpower 125 can deliver from 50 to 125
9 H.P. VANGUARD
amps of welding output current . Output can be
adjusted by setting the current control dial on the
NO LOAD. 0.15 GALLONS/HOUR
2400 R.P.M (.57 LITERS/HOUR) output control panel.
NO LOAD 0.33 GALLONS/HOUR You can get maximum welding output by setting the
3750 R.P.M. (1.25 LITERS/HOUR
dial to 125 AMPS. At high current settings like this,
DC CC WELD OUTPUT 0.63 GALLONS/HOUR
some output may decrease as the machine is used.
100 AMPS, 25 VOLTS (2.4 LITERS/HOUR
If you are welding for a long time, you may need to
DC CC WELD OUTPUT 0.76 GALLONS/HOUR turn the dial slightly upward to maintain the same
125 AMPS, 25 VOLTS (2.9 LITERS/HOUR)
results.
AUXILIARY POWER 0.76 GALLONS/HOUR The numbers on the dial correspond to the
4500 KVA (2.9 LITERS/HOUR)
approximate amps needed to weld using specific
Lincoln welding rods. Table B.2, WELDING
(For Codes 11183, 11406) APPLICATIONS, or the electrode selection guide on
the machine output panel give you the recommended
Robin / Subaru
dial settings based on the thickness of the work and
9 H.P. EX 27
the size and type of rod you’re using.
NO LOAD 0.31 GALLONS/HOUR
TO USE THE WELDANPOWER 125 FOR WELDING:
3750 R.P.M. (1.17 LITERS/HOUR
DC CC WELD OUTPUT 0.66 GALLONS/HOUR
1. Remove the flange nuts from the weld output
100 AMPS, 25 VOLTS (2.48 LITERS/HOUR
terminals and place the work and electrode
DC CC WELD OUTPUT 0.70 GALLONS/HOUR welding cables over the terminals. See Figure
125 AMPS, 25 VOLTS (2.66LITERS/HOUR)
B.1 and B.1a. Replace and tighten the flange
nuts securely. Be sure the connections are tight.
AUXILIARY POWER 0.68 GALLONS/HOUR
4250 KVA (2.59 LITERS/HOUR)
WELDANPOWER 125
� 14 �
OPERATION
120V Receptacle Operation:
2. Select the appropriate electrode. See Table B.2 or
the ELECTRODE SELECTION GUIDE on the
� Set the Output Control on the Pro-Cut 25 no higher
machine Output Control Panel.
than the 15 amp position.( Higher settings may cause
3. Attach the work clamp securely to the work you are
circuit breaker on the Weldanpower 125 to trip.)
welding.
� Maximum material thickness that can be cut is 1/4".
4. Insert the electrode into the electrode holder.
5. Set the current control dial to the desired output
240V Receptacle Operation:
current.
6. Start the gasoline engine. See ENGINE
� The Pro-Cut 25 may be used for its full range of
OPERATION in this section of the manual.
control.
7. Strike an arc and begin welding.
� Maximum material thickness that can be cut is 3/8".
AFTER YOU FINISH THE WELD:
1. Stop the gasoline engine. See ENGINE
(Codes 10158, 10160 Only)
OPERATION in this section of the manual.
Semi-automatic Wire Welding with a Lincoln Wire
2. Allow the electrode and work to cool completely.
Feeder/Welder
3. Remove the work clamp from the work.
4. Remove any remaining piece of electrode from the
The Weldanpower 125 generator power can be used to
electrode holder.
supply up to 4,500 watts continuous input power to a
5. If you are finished using the WELDANPOWER 125
Lincoln Wire Feeder/Welder. The Wire Feeder/ Welder is
for welding, disconnect the welding cables from the
equipped with all the supplies needed for Flux-Cored Arc
weld output terminals. Reattach the flange nuts and
Welding (FCAW). Also some Wire Feeder/Welders come
leave them on the terminals.
equipped with the essentials needed for Gas Metal Arc
For DC+ welding, the electrode cable is to be connected
Welding (GMAW) or MIG processes, while others require
to the �+� output stud and work cable to the �-� output
the purchase of a conversion kit. These products are
stud. (For DC- welding, reverse these connections.)
available where Lincoln products are sold. Contact your
local authorized Lincoln representative for more details.
(For Codes 11183, 11406 Only)
Semi-automatic Wire Welding with a
(Codes 10158, 10160 Only)
Lincoln Wire Feeder/Welder
Plasma Cutting with Lincoln Pro-Cut 25.
The Weldanpower 125 generator power can be used to
The Weldanpower 125 generator power can be used to
supply up to 4,250 watts continuous input power to a
supply up to 4,500 watts continuous input power to a
Lincoln Wire Feeder/Welder. The Wire Feeder/ Welder is
Pro-Cut 25. The Pro-Cut will work satisfactorily under the
equipped with all the supplies needed for Flux-Cored Arc
following conditions:
Welding (FCAW). Also some Wire Feeder/Welders come
equipped with the essentials needed for Gas Metal Arc
1. Set the Rheostat on the Weldanpower 125 to the
Welding (GMAW) or MIG processes, while others require
125 amp position. (Higher Settings may result in a
the purchase of a conversion kit. These products are
shutdown of the Pro-Cut 25.)
available where Lincoln products are sold. Contact your
local authorized Lincoln representative for more details.
2. Leave the "ON/OFF" switch on the Pro-Cut "OFF"
until the Weldanpower 125 has been started and is
(For Codes 11183, 11406 Only)
at full operating speed.
Plasma Cutting with Lincoln Pro-Cut 25.
115V Receptacle Operation:
The Weldanpower 125 generator power can be used to
supply up to 4,250 watts continuous input power to a
� Set the Output Control on the Pro-Cut 25 no higher
Pro-Cut 25. The Pro-Cut will work satisfactorily under the
than the 15 amp position.( Higher settings may cause
following conditions:
circuit breaker on the Weldanpower 125 to trip.)
� Maximum material thickness that can be cut is 1/4".
1. Set the Rheostat on the Weldanpower 125 to the
125 amp position. (Higher Settings may result in a
230V Receptacle Operation:
shutdown of the Pro-Cut 25.)
� The Pro-Cut 25 may be used for its full range of
2. Leave the "ON/OFF" switch on the Pro-Cut "OFF"
control.
until the Weldanpower 125 has been started and is
� Maximum material thickness that can be cut is 3/8".
at full operating speed.
WELDANPOWER 125 � 15 �
OPERATION
AUXILIARY POWER OPERATION Electrical loads in watts are calculated by multiplying
the voltage rating of the load by the number of amps
WARNING it draws. (This information is given on the load device
nameplate.) For example, a device rated 120 volts, 2
amps will need 240 watts of power (120 x 2 = 240).
Be sure that any electrical equipment plugged into
the generator AC power receptacles can withstand a
You can use Table B.3, AUXILIARY POWER
±10% voltage and a ±5% frequency variation. Some
APPLICATIONS, to determine the wattage
electronic devices cannot be powered by the
requirements of the most common types of loads you
WELDANPOWER 125. Refer to Table A.2,
can power with the WELDANPOWER 125. Be sure to
ELECTRICAL DEVICE USE WITH THE
read the notes at the bottom of the table.
WELDANPOWER 125, in the INSTALLATION section
of this manual.
TO USE THE WELDANPOWER 125 AS AN
AUXILIARY POWER SUPPLY:
GENERAL INFORMATION
1. Start the gasoline engine. See ENGINE
(For Codes 10158, 10160)
OPERATION in this section of the manual.
The WELDANPOWER 125 is rated at 4500
2. Set the current control dial on the output control
continuous watts (3500 watts CSA). It provides both
panel to “MAX.� See Figure B.1 and B.1a.
115 volt and 230 volt power. You can draw up to 20
amps (15 amps CSA) from either side of the 115 volt
(For Codes 10158, 10160)
duplex receptacle. Up to 20 amps (15 amps CSA) can
3. Plug the load(s) into the appropriate 115 volt or
be drawn from the single 230 volt receptacle.
230 volt power receptacle.
Electrical loads in watts are calculated by multiplying (For Codes 11183, 11406)
the voltage rating of the load by the number of amps 3. Plug the load(s) into the appropriate 120 volt or
it draws. (This information is given on the load device 240 volt power receptacle.
nameplate.) For example, a device rated 115 volts, 2
amps will need 230 watts of power (115 x 2 = 230). NOTE: During welding, the maximum generator output for auxiliary
loads is 100 watts.
(For Codes 11183, 11406) (For Codes 10158, 10160)
The WELDANPOWER 125 is rated at 5500 surge NOTE: You can supply multiple loads as long as the total load
watts or 4250 continuous watts. It provides both does not exceed 4,500 watts). Be sure to start the largest
loads first.
120 volt and 240 volt power. You can draw up to 20
(For Codes 11183, 11406)
amps from either side of the 120 volt duplex NOTE: You can supply multiple loads as long as the total load
receptacle, but not more than 35.4 amps from both does not exceed 5,500 surge watts or 4000 continuous
sides at once. Up to 17.7 amps can be drawn from watts. Be sure to start the largest loads first.
the single 240 volt receptacle.
TABLE B.2
ELECTRODE SELECTION GUIDE
CURRENT RANGE (AMPS)
AWS ELECTRODE
CLASSIFICATION ELECTRODE TYPE POLARITY
3/32 SIZE 1/8 SIZE 5/32 SIZE
E6010 FLEETWELD® 5P DC+ 50-75 75-125 -
E6011 FLEETWELD® 35 DC+ 50-75 70-110 80-125
E6011 FLEETWELD® 180 DC+ 50-80 55-110 105-125
E6013 FLEETWELD® 37 DC± 70-95 100-125 -
E7018 EXCALIBUR® 7018 DC+ 70-100 90-125 -
E7018 JETWELD® LH-73 DC+ 65-85 90-125 -
E708-17 & E308L-17 BLUE MAX® 308/308L AC-DC DC+ 50-60 55-95 80-125
ENi-CI SOFTWELD® 99Ni DC+ 50-80 80-110 -
- WEARSHIELD® ABR DC+ - 50-125 -
1/8 AND
SHEET THICKNESS THINNER 1/8 AND THICKER
S19718
3-1-91
WELDANPOWER 125
� 16 �
OPERATION
TABLE B.3
AUXILIARY POWER APPLICATIONS
Suggested Power Applications Running Watts *Start-up Watts
(Continuous) (Surge)
*Air Compressor - 1 HP 2,000 4,000 - 8,000
*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 - 1 HP 1,000 2,500 - 4,000
*Sump Pump 600 1,500 - 2,400
Toaster 1,100
Weed Trimmer 500
Lincoln 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 that uses
a motor, listed in the table, multiply RUNNING WATTS by 2.
(For Codes 10158, 10160)
Multiple loads can be used as long as the total load does not exceed 4,500 watts. Be sure to start the
largest loads first.
(For Codes 11183, 11406)
Multiple loads can be used as long as the total load does not exceed 5,500 surge watts or 4000
continuous watts . Be sure to start the largest loads first.
WELDANPOWER 125 � 17 �
ACCESSORIES
(For Codes 10158 and 10160 only)
OPTIONS/ACCESSORIES
BRIGGS AND STRATTON ACCESSORIES
The following options/accessories are available for
your WELDANPOWER 125 from your local Lincoln The following options/accessories are available for
Distributor: your WELDANPOWER 125 from your local Briggs and
Stratton Distributor:
Accessory Kit (K875) � Includes the following:
Exhaust Deflector - Briggs and Stratton Part No. 710281
� Twenty feet (6.1 meters) of #6 AWG electrode
cable with lug.
� Fifteen feet (4.6 meters) of #6 work cable with lugs.
� Work Clamp
� Headshield with No. 10 filter
� Insulated electrode holder and sample electrodes
150 amp capacity.
Undercarriage (K882-2) - A two-wheeled, hand
movable undercarriage is available for field
installation.
Rotor Removal Kit (S20925) - A service kit with thru
bolt and impact bolt’s for removing the generator rotor
from tapered engine crank shaft.
WELDANPOWER 125
� 18 �
MAINTENANCE
SAFETY PRECAUTIONS OIL: Check the oil level after every 5
hours of operation or daily. BE SURE
TO MAINTAIN THE OIL LEVEL.
WARNING Change the oil the first time after 5 hours of operation
for Briggs & Stratton , 20 hours for the Robin / Subaru
� Have qualified personnel do all maintenance and Then, under normal operating conditions, change the
troubleshooting work. oil after every 50 hours or once a year, whichever
occurs first. If the engine is operated under heavy
� Turn the engine off before working inside the
load or in high ambient temperatures, change the oil
machine.
every 25 hours.
� Remove guards only when necessary to perform
Drain the oil from the drain plug located on either side
maintenance and replace them when the
of the engine bottom, as shown in Figure D.1. Refill
maintenance requiring their removal is complete.
through the oil fill plug until the oil reaches the full
� If guards are missing from the machine, get mark on the dip stick. See Engine Owner’s manual
replacements from a Lincoln Distributor. See the for specific oil recommendations
EXPLODED VIEW AND PARTS LIST at the back of
FIGURE D.1 - OIL DRAIN AND
this manual.
REFILL LOCATION
-------------------------------------------------------------
Read the Safety Precautions in the front of this
manual and in the Briggs & Stratton or Robin /
OIL
Subaru Operating and Maintenance Instructions
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
Do not screw in
starting, operating, or repairing this machine. FILL to FULL mark on
dipstick to check oil dipstick - recheck
ROUTINE AND PERIODIC
12 mm
MAINTENANCE HEX
ENGINE MAINTENANCE
CAUTION Drain
plug
OIL DRAIN
PLUG
To prevent the engine from accidentally starting,
Tighten dipstick Oil drain
disconnect the spark plug lead before servicing the firmly before starting
engine.
FUEL: At the end of each day’s use,
refill the fuel tank to minimize moisture
See the Briggs & Stratton or Robin / Subaru Owner’s
condensation and dirt contamination in
manual for a summary of maintenance intervals for
the fuel line.
the engine. Follow either the hourly or the calendar
intervals, whichever come first. More frequent AIR CLEANER: With normal operating
service may be required, depending on your specific conditions, the maintenance schedule for
application and operating conditions. The Briggs & cleaning and re-oiling the foam pre-filter
Stratton and Robin / Subaru Owner’s manual shows is every 25 hours and replacement of the
engine maintenance replacement parts and numbers. air cleaner filter element every 100 hours.
More frequent servicing is required with dusty
operating conditions. Refer to the maintenance
section of the Engine Owner’s Manual for more
information.
WELDANPOWER 125 � 19 �
MAINTENANCE
To service the pre-cleaner:
Engine Maintenance Parts
Remove the wing nuts and cover for Codes 10158,
10160) (For Codes 10158, 10160)
B & S Vanguard® 9 HP
Remove the cover for (Codes 11183, 11406).
Air Filter Element B & S 710266
Carefully remove the foam pre-cleaner from the filter
Air Filter Pre-Cleaner B & S 710268
element.
Spark Plugs B & S 491055
1. Wash in liquid detergent and water. (Resistor Type) Champion RC12YC
Autolite 3924
2. Squeeze dry in a clean cloth.
(Gap .030� [.76mm])
3. Saturate in clean engine oil.
4. Squeeze in a clean, absorbent cloth to remove all
excess oil.
(For Codes 11183, 11406)
Robin / Subaru
Carefully place the pre-cleaner back over the filter
Air Filter Element 279-32616-00
element and reinstall the air cleaner cover and wing
Air Filter Pre-Cleaner 279-32611-00
nuts.
Spark Plug NGK BR6 HS
CLEAN ENGINE: Remove dirt and debris with a cloth
(Resistor Type) (Gap .030� [.76mm])
or a brush. Do not clean with a forceful spray of
water. Water might contaminate the fuel system. Use
low pressure air to blow out the machine periodically.
In particularly dirty locations this may be required
once a week.
WARNING
Engine Adjustments
OVERSPEED IS HAZARDOUS - The maximum
allowable high idle speed for this machine is 3750
RPM, no load. Do NOT tamper with the governor
components or setting or make any other
adjustments to increase the maximum speed. Severe
personal injury and damage to the machine can
result if operated at speeds above maximum.
------------------------------------------------------------------------
Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorize Field Service
Shop.
Slip Rings
A slight amount of darkening and wear of the slip rings
and brushes is normal. Brushes should be inspected
CAUTION
when a general overhaul is necessary. If brushes are
to be replace, clean slip rings with a fine emery paper.
Do not attempt to polish slip rings while engine is
running.
------------------------------------------------------------------------
Hardware
Both English and Metric fasteners are used in this
welder.
WELDANPOWER 125
� 20 �
TROUBLESHOOTING
How To Use Troubleshooting Guide
WARNING
This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs
performed on this equipment may result in danger to the technician and machine operator and will invalidate your
factory warranty. For your safety, please observe all safety notes and precautions detailed in the Safety Section of
this manual to avoid electrical shock or danger while troubleshooting this equipment.
___________________________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. CONSULT LOCAL AUTHORIZED FIELD
locate and correct possible machine misadjustments. SERVICE FACILITY
Simply follow the three-step procedure listed below. If you have exhausted all of the recommended tests in
step 2, consult your local Authorized Field Service
Step 1. LOCATE PROBLEM (SYMPTOM) Facility.
Look under the column labeled “PROBLEM
(SYMPTOMS)�. This column describes possible
symptoms that your machine may exhibit. Find the
listing that best describes the symptom that your
machine is exhibiting.
Step 2. PERFORM EXTERNAL RECOMMENDED
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.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
WELDANPOWER 125 � 21 �
TROUBLESHOOTING
Observe Safety Guidelines Troubleshooting Guide
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major Physical or Electrical 1. Contact your local Lincoln
Damage is Evident. Authorized Field Service Facility
No generator power or welding 1. Check brushes for wear. See
output. Maintenance section.
2. Check for loose or faulty
connections at brush holders.
3. Open lead in flashing or field
circuit.
4. Rheostat (R1) lead broke.
5. Dirty slip rings.
6. Faulty rheostat (R1).
7. Faulty field bridge rectifier (D1). If all recommended possible areas
8. Faulty field capacitor (C1). of misadjustment have been
9. Faulty stator field winding. checked and the problem persists,
10. Faulty rotor. Contact your local Lincoln
Authorized Field Service Facility.
Generator power is available 1. Loose connection to output stud.
but unit will not weld. 2. Work not connected.
3. Electrode holder loose.
4. No open circuit voltage at output
studs. Open lead in weld circuit.
5. Faulty output bridge rectifier.
6. Faulty choke (L1).
Unit will weld but low or no 1. Circuit breaker is open.
generator power is available. 2. Loose or open connection with
electrical plug-in component.
3. Current control dial not at "MAX"
4. No open circuit voltage at
receptacle.
No auxiliary power but machine has 1. Check CB1 and CB2 - Reset if
weld output tripped.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
WELDANPOWER 125
� 22 �
TROUBLESHOOTING
Observe Safety Guidelines Troubleshooting Guide
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
ENGINE PROBLEMS
Engine will not idle down to low 1. Idler Switch on HIGH Idle.
speed. (For Codes 10158, 10160 2. Engine choke is not fully open.
only.) 3. External load on welder or
auxiliary power. - Remove load.
4. Machine output is under load or
idle switch in wrong position.
5. Idle solenoid does not pull in.
Engine idles down to low idle but 1. Engine low idle RPM may be set
will not stay at low idle. (For Codes too low. - Contact Lincoln Field
10158, 10160 only.) Service Facility.
Engine will not go to high idle when 1. Check Work and Electrode
attempting to weld or use generator cables for loose or faulty If all recommended possible areas
power. (For Codes 10158, 10160 connections. of misadjustment have been
only.) 2. Mechanical linkage from checked and the problem persists,
solenoid to engine stuck. Contact your local Lincoln
3. Open connection in weld circuit. Authorized Field Service Facility.
4. No output from receptacles or
load too small.
5. Idler pc board is not sensing
output current.
6. Faulty idler pc board.
Engine will not go to high idle when 1. Auxiliary load less than 100
using auxiliary power. (For Codes watts.
10158, 10160 only.) 2. Circuit breaker CB1 or CB2
tripped or faulty.
3. Mechanical linkage from
solenoid to engine stuck.
Engine runs erratic or stops running 1. Oil level may be low activating
or engine surges at low idle. (For the engine “Oil Gard� shutdown
Codes 10158, 10160 only.) system. - Check oil level.
2. Idle solenoid linkage or engine
idle misadjusted.
Recoil starter is hard to pull. 1. Crankcase may be over-filled
with oil. - Check oil level.
Engine will not start or starts but 1. Water in engine from rain and / or
runs rough with low power. condensation. - Remove spark plug and
dry it if wet. Blow low pressure compressed
air in spark plug port while pulling recoil
starter. Re-install spark plug.
2. Spark plug may be faulty.
3. Air filter element saturated with water and /
or oil - Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
WELDANPOWER 125 � 23 �
TROUBLESHOOTING
Observe Safety Guidelines Troubleshooting Guide
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
WELDING PROBLEMS
Engine runs erratically or stops 1. Engine is not fully warmed-up
running. and engine choke is in the fully
open (RUN) position.
2. Engine requires service to head,
carburetor, filters, oil, spark plug
and / or gas.
3. Oil level to low.
Engine sputters but will not start. 1. Bad gas, bad filter, air cleaner,
spark plug, and/or breather.
Recoil starter is hard to pull. 1. Too much oil in crankcase.
If all recommended possible areas
Arc is erratic and “pops out�. 1. Check Work and Electrode of misadjustment have been
cables for loose or faulty checked and the problem persists,
connection. Contact your local Lincoln
Authorized Field Service Facility.
2. Electrode may be wet.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact your local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
WELDANPOWER 125
� 24 �
WIRING DIAGRA M - WELDANPOWER 12 5 (FOR CODES 10158, 10160) BRIGGS AND STRATTON
201B
RED 203
209
ORIENT WIRES
4 3 J1
10
3A & 6A 6
AS SHOWN
16
203 BRN 209
L1
IDLER P.C.
WELDANPOWER 125
2 1
(+) J2 5 1 BOARD
14
CHOKE
204
D2 9B
BRN
208 208
200A
BLK
202A IDLER
(-)
SOLENOID
BLK
204
RED
201B CURRENT TRANS. WHITE 3.3 Y
BLK
(+) (-) 100 W
200B 200
RED
W1 BLK ROTOR
RED
202B 201B
R1
OUTPUT STUDS
RED
BLK CCW
RED
RED
FRONT 202A
(+)
202 (+) 200C
SOLENOID STATOR 16
GROUND BRACKET W2 +
GROUND (-) BRN 9B D1
PANEL GND-D
GND-C
� 25 �
GREEN GREEN C1 600 FD
201A 7A HOUR METER
HI
5
6 3 7 9
15 201
BLK BLK (-) 201C
9A
6 5 BLK
3 1 AUTO
4
2 15A IDLE
ELECTRICAL
SWITCH
CB2 20A SYMBOLS
BROWN
WHITE
BLK
(15A CSA) 6A PER E1537
14
BLUE
BLK
5A
WHITE 3A
6A
WIRING DIAGRAM
CB1 20A ENGINE WIRING
14A
6B (15A CSA)
BLK
6C 3B
3C
GND-B
GREEN
BLK
J3 NOTE:
ALL CASE FRONT
J4 COMPONENTS SHOWN
GND-A
115 VOLT MODULE
MAG
230 VOLT VIEWED FROM REAR.
GREEN
3C
RUN/STOP OIL LEVEL
5A
SWITCH SWITCH
3B
WHITE TERMINALS
BLK
2-15-2002J
S21455
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
)
� 26 �
WIRING DIAGRAM
Enhanced Diagram
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
WELDANPOWER 125
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
WIRING DIAGRAM - WELDANPOWER 125 (FOR CODE 11406)
201B
L1 203
(+)
SUPPRESSOR
CHOKE
ASSEMBLY
D2
WELDANPOWER 125
204
(-)
3.3 Y 200
ROTOR 100 W
200A
(+) (-) R1 202B
(+) CCW
A.01 (+)
202
202A
W1 (+)
200C
(-) D3
+
201B D1
201A C1 600 FD
FRONT SOLENOID STATOR (-)
PANEL BRACKET 201 HOUR METER
W2
GROUND (-)
GROUND 201C
7A
9A
GND-D GND-C 205
� 27 �
6 5 7 15
3 9
CB2
4
3 1 2
6
20A 5
GND-A ELECTRICAL
9A
6A 5A 3A SYMBOLS
7A
GND-B PER E1537
WIRING DIAGRAM
6B CB1 20A
3C ENGINE WIRING
6C
MODULE
3B
J3 MAG RUN/STOP
LOW OIL
SW ITCH
SWITCH
J4
120 VOLT
240 VOLT GND-A
3C
5A
3B
NOTE:
WHITE TERMINALS
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
A
S26831
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
20.00 30.00
REF. REF.
508 762
21.13
REF.
537
� 28 �
R
LINCOLN
ELECTRIC
DIMENSION PRINT
2-17-95
7.92 13.62
REF. REF. M17614
201 346
WELDANPOWER 125
NOTES
WELDANPOWER 125
� 29 �
NOTES
WELDANPOWER 125
� 30 �
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa fuera del área de trabajo. cuerpo.
mojada.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
vêtements mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e G Mantenha inflamáveis bem G Use proteção para a vista, ouvido e
electrodos com a pele ou roupa guardados. corpo.
ATENÇÃO molhada.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES
HERSTELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
� 31 �
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de G Desconectar el cable de G No operar con panel abierto o
AVISO DE
respiración. alimentación de poder de la guardas quitadas.
G Mantenga la cabeza fuera de los máquina antes de iniciar cualquier
PRECAUCION
humos. Utilice ventilación o servicio.
aspiración para gases.
French
G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Débranchez le courant avant
G Utilisez un ventilateur ou un ouverts ou avec les dispositifs de
ATTENTION
l’entretien. protection enlevés.
aspirateur pour ôter les fumées des
zones de travail.
German
G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
G Strom vor Wartungsarbeiten oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und abschalten! (Netzstrom völlig Betrieb setzen!
öffnen; Maschine anhalten!)
Entlüftung des Arbeitsplatzes!
Portuguese
G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Não opere com as tampas removidas.
G Use ventilação e exhaustão para moventes.
ATENÇÃO
G Desligue a corrente antes de fazer G Não opere com os paineis abertos
remover fumo da zona respiratória.
serviço. ou guardas removidas.
G Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� 32 �
� World's Leader in Welding and Cutting Products �
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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