Lincoln Electric WELDMARK 225 IM927 manual

WELDMARK 225 O P E R A TO R ’ S M A N U A L For Machines with Code Number 11396 IM927 January, 2007 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. D O N O T I N S T A L L , O P[...]

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. ________________________________________________[...]

ii SAFETY ii ARC RA YS 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 ski[...]

FOR ELECTRICALL Y 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[...]

Mar. ‘93 iv SAFETY iv WELDMARK 225 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse élect[...]

v v Thank for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay par[...]

vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ...........................[...]

A-1 INST ALLA TION WELDMARK 225 A-1 WELDMARK 225 TECHNICAL SPECIFICA TIONS - Weldmark 225 (K2239-4 ) INPUT - GASOLINE ENGINE RA TED OUTPUT @ 104°F (40°C) FOR WELDER HEIGHT WIDTH DEPTH WEIGHT 30.3 in. 19.1 in. 42.3 in. 502 lbs. (228kg) 770 mm 485 mm 1074 mm RA TED OUTPUT @ 104°F (40°C) FOR GENERA T OR Welding Output AC Constant Current 225A / 25[...]

A-2 INST ALLA TION A-2 SAFETY PRECAUTIONS MACHINE GROUNDING Because this portable engine driven welder or genera- tor creates it’s own power, it is not necessary to con- nect it’s frame to an earth ground, unless the machine is connected to premises wiring (your home, shop, etc.). To prevent dangerous electric shock, other equip- ment to which [...]

3. Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself while being operated or serviced. 4. Typical conditions of use, i.e., travel speed; rough- ness of surface on which the trailer will be operated; environmental conditions. 5. Conformance with federal, s[...]

WELDING OUTPUT CABLES With the engine off, connect the electrode and work cables to the studs provided. These connections should be checked periodically and tightened if neces- sary. Loose connections will result in overheating of the output studs. When welding at a considerable distance from the welder, be sure you use ample size welding cables. L[...]

A-5 INST ALLA TION A-5 e. Place the Engine switch in the “Auto Idle” position. f. Adjust the wire feed speed at the LN-15 and adjust the welding voltage with the output “CONTROL” at the welder. Output “CONTROL” must be set above 3. Note: LN-15 Control Cable model will not work with the WELDMARK 225. CONNECTION OF THE LN-25 TO THE WELDMA[...]

120 V DUPLEX RECEPTACLES The 120V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any plug used with the system must be at least equal to the current load through the associated receptacle. MOTOR STARTING Most 1.5 hp AC single phase mot[...]

A-7 INST ALLA TION A-7 TABLE lll ELECTRICAL DEVICE USE WITH THE WELDMARK 225. 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. regulati[...]

A-8 INST ALLA TION A-8 STANDBY POWER CONNECTIONS The WELDMARK 225 is suitable for temporary, stand- by, or emergency power using the engine manufactur- er’s recommended maintenance schedule. The WELDMARK 225 can be permanently installed as a standby power unit for 240V-3 wire, single phase 38 ampere service. (Connections mus t be made by a licens[...]

240 Volt 60 Hz. 3-Wire Service POWER  COMPANY  METER 240 VOLT 120 VOLT 120 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION GND N NOTE: No. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS. 240 VOLT G ROUNDED CONDUCTOR 4 0 AMP[...]

WELDER CONTROLS - FUNCTION AND OPERA TION ENGINE SWITCH The engine switch is used to Start the Engine, Select High Idle or Auto Idle while the engine is running, and stop the Engine. When placed in the “OFF” position, the ignition circuit is de-energized to shut down the engine. When held in the “START” position, the engine starter motor is[...]

“ RANGE” SWITCH The “Range” switch is used to select one of three amperage ranges with generous overlap for Stick/TIG welding, or one Wire Feed welding range. Never change the “RANGE” Switch setting while welding. This will damage the switch. ------------------------------------------------------------------------ “ CONTROL” DIAL Pr[...]

B-3 OPERA TION B-3 ST ARTING/SHUTDOWN INSTRUCTIONS STARTING THE ENGINE Be sure all Pre-Operation Maintenance has been per- formed. Also, read the Engine Owner’s Manual before starting for the first time. Remove all loads connected to the AC power recepta- cles. Use the choke control as follows: KOHLER ENGINE - Always pull the choke control out wh[...]

B-4 OPERA TION B-4 WELDING PROCESS For any electrodes the procedures should be kept within the rating of the machine. For electrode infor- mation see the appropriate Lincoln publication. STICK (CONSTANT CURRENT) WELDING Connect welding cables to the "TO WORK” and "ELECTRODE” studs. Start the engine. Set the "Polarity” switch [...]

B-5 OPERA TION B-5 SUMMARY OF WELDING PROCESSES CONTROL ELECTRODE CABLE IDLE WHEN NOT TO START PROCESS USED MODE WELDING WELDING STICK No AUTO Hot Touch electrode to work. Welding starts immediately and engine goes to high idle. WIRE FEED, LN-15 No AUTO Cold Press gun trigger. ACROSS the ARC LN-15 contactor closes, (has internal contactor) Welding [...]

C-1 ACCESSORIES C-1 OPTIONAL EQUIPMENT (Field Installed) K957-1 Heavy Duty, Two Wheel Trailer For Small Welders - For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.) Order K957-1 Trailer K958-1 Ball Hitch K958-2 Lunette Eye Hitc[...]

C-2 ACCESSORIES C-2 RECOMMENDED EQUIPMENT STICK K704 or K875 Accessory Kit (See Accessory page C-1 for items included in Kit.) WIRE FEED K44 9 L N-2 5 - In clu des int erna l cont acto r f or acro ss the arc operation (no control cable). Provides “cold” electrode until gun trigger is pressed. Includes gas solenoid. Magnum Gun and Magnum Gun[...]

Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. 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 mainte- nance requiring their removal is complete. Always use the greatest care when working [...]

D-2 MAINTENANCE D-2 Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SG or SH. Always check the API SERVICE label on the oil con- tainer to be sure it includes the letters SG or SH. SAE 10W-30 is recommended for general, all-tempera- ture use, -5 F to 104 F (-20 C to 40 C). See Engine Owner’s Manual for[...]

D-3 MAINTENANCE D-3 ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3750 RPM, no load. Do NOT tamper with 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. ---[...]

E-1 TROUBLESHOOTING E-1 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. CAUTION This Troubleshooting Guide is provided to help you l o c a t e a n d r e p a i r p o s s i b [...]

E-2 TROUBLESHOOTING E-2 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBLEMS (SYMPTOMS) POSSIBLE CA[...]

E-3 TROUBLESHOOTING E-3 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBLEMS (SYMPTOMS) POSSIBLE CA[...]

F-1 WIRING DIAGRAMS F-1 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. WELD[...]

F-2 DIAGRAMS F-2 WELDMARK 225 WELDMARK 225 / / L L N N - - 1 1 5 5 AND LN-25 ACROSS T AND LN-25 ACROSS T H H E ARC CONNECT E ARC CONNECT I I O O N DI N DI AGRAM AGRAM ELECTRIC SHOCK can ELECTRICSHOCKcan kill kill Do not operate Donotoperate with panels open. withpanelsopen. Di Di s s connect NEGATIVE connectNEGATIVE ( ( - - ) Bat )Bat tery tery lea[...]

F-3 DIMENSION PRINT F-3 WELDMARK 225 (KOHLER) M20267 C. 01 26.59 30.27 9.099.09 17.00 21.22 8.80 30.00 42.00 22.15 10.33 CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK 9.31 CENTERLINE OF SHAFT 9.59 10.19 OIL FILTER REMOVAL NOTE: CASEFRONT GRAPHICS MAY NOT MATCH ALL CODES. 42.25 W E L DM AR K 22 5 (K O H LE R ) M 20 2 6 7 C . 01 26.5 9 30.2[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA EL [...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁ TICAS DE SEGURANÇA DO EMPREGADOR. l Keep your head out of fumes . l Use ventil atio n or ex haust to remo ve fum es[...]

• Manufactured by Lincoln Electric Company • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com WELDMARK 225[...]