Lincoln Electric SVM 113-A service manual Operation, Operating Instructions, Safety Instructions

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B-2

B-2

OPERATION

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OPERATING INSTRUCTIONS

Read and understand this entire section before oper- ating your WELDANPOWER 125.

SAFETY INSTRUCTIONS

WARNING

WARNING

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Do not attempt to use this equipment until you have

 

ENGINE EXHAUST can kill.

thoroughly read all the operation and maintenance

 

 

 

manuals supplied with your machine. They include

 

• Use in open, well ventilated areas or

important safety precautions; detailed engine starting,

 

vent exhaust to the outside.

operating, and maintenance instructions; and parts

 

• Do not stack anything on or near the

lists.

 

 

engine.

 

 

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Return to Section TOC

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ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrodes with your skin or wet cloth- ing.

Insulate yourself from the work and ground.

Always wear dry insulating gloves.

FUMES AND GASES can be dan- gerous.

• 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.

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 ser- vice this equipment.

GENERAL DESCRIPTION

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

WELDANPOWER 125

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Contents Weldanpowertm Safety California Proposition 65 WarningsElectric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications WeldanpowerLocation and Ventilation Safety PrecautionsStoring PRE-OPERATION Engine Service Electrical Output Connections Welding Cable ConnectionsMachine Grounding Auxiliary Power ReceptaclesPlugs and HAND-HELD Equipment Premises Wiring Circuit BreakersThese Devices Without Table of Contents Operation Section Safety Instructions OperationOperating Instructions General DescriptionOperational Features and Controls Design Features AdvantagesRecommended Applications Welding CapabilityControls and Settings WELDER/GENERATOR ControlsGasoline Engine Controls Figure B.2 Gasoline Engine ControlsBefore Starting the Engine Engine OperationStarting the Engine Stopping the Engine For Best Engine StartingWelding Operation BREAK-IN PeriodGeneral Information LOW OIL SensingTo USE the Weldanpower 125 for WELD- ING TIG WeldingTable B.2 Electrode Selection Guide Auxiliary Power To USE the Weldanpower 125 AS AN Auxiliary Power SupplyTable B.3 Generator Power Applications Table of Contents Accessories Lincoln Electric Accessories OPTIONS/ACCESSORIESBriggs and Stratton Accessories Table of Contents Maintenance Routine and Periodic Maintenance Engine MaintenanceFigure D.3 Clean Finger Guard MaintanenceFigure D.5 SET Spark Plug GAP WELDER/GENERATOR Maintenance Table D.2 Engine Maintenance PartsFigure D.6 Major Component Locations Table of Contents Theory of Operation Section ENGINE, EXCITATION, Rotor and Stator Idler BoardRotor Field Feedback Auxiliary Power Engine Idle Control Auxiliary Power Overcurrent ProtectionWeld WINDING, Output Rectifier and Choke Figure E.4 Weld WINDING, Output Rectifier and ChokeTable of Contents Trouble Shooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Electric Shock can killTroubleshooting Guide Output ProblemsOutput Rectifier Troubleshooting & Repair Perform the Engine Throttle Engine Problems Main Stator Winding Test Engine Throttle Adjustment Troubleshooting & Repair Weldanpower Test Description Rotor Voltage TestMaterials Needed Test Procedure Rotor Voltage TestRotor Resistance Test Rotor Resistance Test Figure F.3 Brushes Retained with Cable TIE Output Rectifier Bridge Test Output Rectifier Bridge Test Main Stator Test Main Stator Test Figure F.6 Main Stator Molex Plug Test Points Rotor Flashing Circuit Test Rotor Flashing Circuit Test WP125 Idler Engine Throttle Adjustment Test Test Procedure Figure F.12 Idle Speed Adjustment Screw Locations Figure F.13 LOW Idle Adjustment NUT on Idler Solenoid TOC Normal Open Circuit Weld Voltage Waveform Scope SettingsHigh Idle no Load Output Control AT Maximum Normal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded Typical Weld Output WaveformMachine Loaded to 125 Amps AT 25 VAC Abnormal Open Circuit Weld Voltage Waveform Brush Removal and Replacement DescriptionProcedure Figure F.14 Brushes Retained with Cable TIEProcedure Rheostat Removal and Replacement Rheostat Removal and Replacement Field Capacitor Removal and Replacement Field Capacitor Removal and Replacement Field Diode Bridge Removal and Replacement Field Diode Bridge Removal and Replacement Figure F.18 Field Diode Bridge Location Idler Printed Circuit Board Removal Replacement Carefully remove the board Output Rectifier Bridge Removal Replacement Output Rectifier Bridge Removal and Replacement Troubleshooting & Repair Output Choke Removal and Replacement Output Choke Removal and Replacement Section TOC STATOR/ROTOR Removal and Replacement InstructionsStator Removal Procedure Troubleshooting & Repair Rotor Removal Procedure Reassembly ProcedureFigure F.24 Checking ROTOR-STATOR AIR GAP Feeler Gauge Troubleshooting & Repair Auxiliary Power Receptacle OUTPUT1 Retest After RepairEngine Output WELDER/GENERATOR OUTPUT1Weldanpower Table of Contents Diagrams Section Wiring Diagram Code 10158 Schematic DiagramsIdler PC Board M17578 Dimension Print Weldanpower Weldanpower M17578 Idler PC Board M17578-1M17578 Idler PC Board Bill of Materials DescriptionWeldanpower