LINCOLN LINCWELDER 225 CCKA (01) PDF MANUAL

LINCOLN LINCWELDER 225 CCKA (01) PDF SUMMARY:

What safety precautions should be taken when working with the Lincwelder 225?

Before working on the equipment, turn off the input power using the disconnect switch at the fuse box. Install equipment in accordance with the National Electrical Code, all local codes and the manufacturer’s recommendations. Ground the equipment in accordance with the National Electrical Code and the manufacturer’s recommendations.

What engine safety precautions are recommended?

Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. 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 refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated. Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts. 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. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate. To avoid scalding, do not remove the radiator pressure cap when the engine is hot. Have all installation, operation, maintenance and repair work performed by qualified people.

Where can I find more detailed safety information?

For more detailed information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting -ANSI Standard Z49. l” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135.

What is the product description for the Lincwelder 225?

The Lincwelder 225 is an Onan aircooled engine driven combination welder/power generator. This machine supplies 40-225 amperes of DC welding current and 3 KW of either 115 or 230 volt, 50 hertz AC auxiliary power, depending upon the model ordered.

Does the Lincwelder 225 need to be grounded?

The 1981 National Electrical Code does not require this machine to be grounded under normal operating circumstances. Some state, local or other codes or unusual operating circumstances may require the machine frame to be grounded. It is recommended that you determine the extent to which such requirements may apply to your particular situation and follow them explicitly. A machine grounding stud marked with the symbol is provided on the welder control panel. In general, if the machine is to be grounded it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into 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 National Electrical Code lists a number of alternate means of grounding electrical equipment.

Do I need to install an exhaust spark arrester on my Lincwelder 225?

Some federal, state or local laws may require that gasoline engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard mufflers included with these welders do not qualify as spark arresters. When required by local regulations, suitable spark arresters must be installed and properly maintained.

What happens if I install the wrong exhaust spark arrester on my Lincwelder 225?

An incorrect arrester may lead to damage of the engine or its performance. Contact the engine manufacturer for specific recommendations.

What steps should be taken when preparing to operate the Lincwelder 225’s engine?

Before starting the engine, be sure the crank case is filled to the proper level with oil. Also, fill the gas tank and open the shut-off valve in the fuel line. Be sure any welding or auxiliary power loads are turned off or disconnected. See the Onan engine operating instructions supplied with the welder, detailed engine starting, operating and maintenance instructions, safety precautions and parts lists.

What type of starters are available for my Lincwelder 225?

Your engine may be equipped with either the standard manual rope pull starter or the optional factory installed electric starter. This electric starter includes a starter button and ammeter located on the control panel and a battery charger circuit. Battery charger circuit information is given on page 4. These machines are furnished with wet batteries.

What precautions should be taken when servicing the batteries?

When servicing batteries, use caution -the electrolyte is a strong acid that can burn skin and damage eyes.

How do I start the engine on my Lincwelder 225?

1. Turn the ignition switch on.
2. Choke per instructions in the Onan engine operator’s manual.
3. a. Machines with optional engine idler – normally, start with the automatic engine idler lever swinging freely so the engine slows to low idle speed upon starting. b. Machines without optional engine idler – normally, start the engine with the “Hi-Lo” lever on the engine shroud set in the “Lo” or slow engine speed position.
4. Start the engine using either the starter button (machines equipped with an electric starter) or the starter rope.

How do I operate the engine and idler on my Lincwelder 225?

Machines with engine idler – For welding, let the automatic engine idler lever swing freely. Upon striking the arc, the engine automatically increases to full speed. When welding is stopped, the idler slows the engine to idle speed after a preset time delay to reduce engine wear and conserve fuel. For AC power output, lock the idler lever in the full speed position using the cotter pin connected to the idler.

NOTE: Full idler operation and maintenance instructions are included in IM-179 supplied with the machine. The carburetor and governor adjusting instructions in IM-179 were written primarily for Lincoln water cooled engine driven welders. See the Onan engine operator’s manual for the corresponding instructions for this machine.

Machines with an engine idler but built before March 1973 (below code 7250) – These machines have a “Hi-Lo” Engine speed control lever on the engine shroud. Always set this lever on “Hi” for proper idler operation.

Machines without engine idler – Engine speed is controlled by the “Hi-Lo” lever on the engine shroud. Set the lever on “Hi” when welding or using the AC power output. Move it to “Lo” to slow the engine to idle speed.

How do I stop the engine on my Lincwelder 225?

Stop the engine by turning the ignition switch off.

What size output cables should I use for my Lincwelder 225?

Use #3 electrode and work cables when welding up to 30 feet from the welder. If welding at a substantially longer distance from the machine, use #2 or larger cable. Long cables of small diameter reduce the output at the point of welding

How do I use polarity control on my Lincwelder 225?

One output stud is marked “Positive” and the other stud is marked “Negative”. If you want to weld with the electrode positive (Reverse Polarity), connect the electrode cable to the positive stud and the work cable to the negative stud. If you want to weld with electrode negative (Straight Polarity), reverse the two cables. Tighten the stud nuts with a wrench.

How do I use the ‘Current Range’ setting on my Lincwelder 225?

The ‘Current Range’ selector is the coarse current adjustment for your welder. There are five positions indicated on the control dial. The numerical value assigned to each position is the center of the current range available at that particular setting. For each setting there is a maximum and minimum current available through the adjustment of the ‘Fine Adjustment’.

How do I use the ‘Fine Adjustment’ setting on my Lincwelder 225?

The ‘Fine Adjustment’ control is the fine current control of your welder. Through this control, you can obtain the exact current you desire. With this control it is also possible to vary the open circuit voltage and thereby change the arc characteristics to suit different welding applications. There is sufficient overlapping of the current ranges obtained with the ‘Current Range’ so the ‘Fine Adjustment’ may be used to vary the arc characteristics. High voltage for a soft arc. Low voltage for a forceful digging arc. For 175 amps and the preferred soft arc, set the ‘Current Range’ to 150 and turn the ‘Fine Adjustment’ up towards 10 to get 175 amps. To obtain 175 amps and a forceful arc, set the ‘Current Range’ at 200 and turn the ‘Fine Adjustment’ down towards 1 to get 175 amps. For most welding you will get the best welding characteristics by using a lower setting on the ‘Current Range’ and a higher setting on the ‘Fine Adjustment’. This will give you a soft arc and high open circuit voltage to prevent pop outs. However, for vertical or overhead welding, a low open circuit voltage is often desired to give a snappy digging arc.

What is the welding duty cycle on my Lincwelder 225?

This machine has a 30% duty cycle at the rated output of 225 amperes. Duty cycle is based on a 10 minute period. Therefore, the welder can be loaded at 225 amperes for 3 minutes out of every 10 minute period. You can use higher duty cycles at lower currents. See the nameplate.

What safety precautions should be taken when thawing pipe with my Lincwelder 225?

Pipe thawing, if not done properly, can result in fire, explosion, damage to wiring which may make it unsafe, damage to pipes, burning up the welder, or other hazards. Do not use a welder to thaw pipe before reviewing Lincoln bulletin E-695.1 (dated December ’76 or later).

How do I ground power tools to my Lincwelder 225?

Power tools should always be grounded to the machine frame unless protected by an approved system of double insulation. The Lincwelder is equipped with 3-prong grounded receptacles.

What are the cautions when using the auxiliary power on my Lincwelder 225?

This 115 or 230 volt, 50 Hertz auxiliary power should not be used for equipment such as fluorescent lights, radios or other electronic devices and motors, appliances or tools designed only for 60 Hertz input. For specific information about the operation of 60 Hertz equipment on 50 Hertz power, contact the equipment manufacturer.

How do I use the 115 Volt models of the Lincwelder 225?

Most of these welders are equipped to produce 115 volt, 50 Hertz, single-phase AC power. This power is suitable for operating incandescent lights and power tools with either universal or 50 Hertz motors. Set the ‘Fine Adjustment’ rheostat on 10 and start the engine. If the optional engine idler is installed, it must be latched in the full speed position. After the engine is running, plug the load into the receptacles on the nameplate. A maximum of 15 amps can be drawn from each side of the duplex receptacles. Attempting to draw more current may damage the receptacles. A maximum total of 26 amps can be drawn from the two receptacles. Attempting to draw more may result in a serious voltage drop causing lights to dim, driven motors to overheat, and may damage the generator. Normally, power tools cannot be run at the same time the machine is used for welding. It is possible to weld at low currents with lights plugged in.

How do I use the 230 Volt models of the Lincwelder 225?

This welder is available equipped to produce 230 volt, 50 Hertz, single-phase AC power rather than 115 volt power. This power is suitable for operating lights, power tools and 50 Hertz motors. Set the ‘Fine Adjustment’ rheostat to 10 and start the engine. If the optional engine idler is installed, it must be latched in the full speed position. After the engine is running, plug the load into the 3-prong receptacles in the nameplate. A maximum of 13 amps can be drawn from the receptacles. It can be drawn from one or split between the two receptacles. Attempting to draw more than 13 amps results in a serious voltage drop causing lights to dim, driven motors to overheat, and may damage the generator.

How does the battery charging circuit work on the Lincwelder 225?

This circuit is part of the optional electric starter. Current for charging the battery is taken from the welding generator. The circuit includes resistors to limit the charging current and a silicon diode to prevent the battery from discharging back through the generator when the machine is not running. The charging circuit wiring diagram is pasted to the inside of the machine cover. If you are undercharging the battery, it cranks the engine slower at each start. If you are overcharging the battery, you have to add water frequently. Overcharging tends to shorten battery life. The nameplate on the welder control panel identifies the electric start controls. Included with the electric start controls is a battery charge rate switch. Units below code 8000 have a two-position switch. It provides a “high” charge rate of approximately 4 to 5 amps or a “low” charge rate of 1.5 to 2 amps. Units above code 8000 have a three-position charge rate switch. It provides a “high” charge rate of approximately 3 amps, a “medium” charge rate of approximately 1.5 amps, and a “trickle” charge rate of approximately 0.5 amps. All charge rates are with the unit running at high idle and the fine adjustment control set for max. O.C.V. The nameplate also gives a guide for the setting of the charge rate switch: “high” for cold weather or frequent starts, “medium” for normal use, and “trickle” for hot weather or long operating periods. If you operate the welder with the batteries disconnected, tape the battery leads to avoid damaging the charging circuit. The ammeter is the best indicator of any trouble in the charging circuit. The ammeter should indicate the charging current when the engine is running and should read zero with the engine stopped. Any other combination of readings indicates trouble.

What do the meter readings mean on my Lincwelder 225?

Meter Readings	Engine Operating	Engine Stopped	Possible Causes
Charge	Discharge	1.	Shorted diode.
Zero	Zero	1.	Diode blown open. 2. Open lead in circuit. 3. Welder generator output polarity reversed (Rare). Call nearest Field Service Shop to correct.
Charge	Charge	1.	Battery connected backwards.

What are the periodic maintenance procedures for the Lincwelder 225?

1. Blow out the welder and controls with low pressure air periodically. In particularly dirty locations, this may be required once a week.
2. Replace the engine crankcase oil every 50 hours of operation.
3. Inspect the air filter every 50 hours of normal operation. Replace element if dirty.
4. Governor and carburetor joints and the throttle shaft must be kept clean and lubricated.
5. The generator bearing is sealed and has its own lubricant. It does not require lubricant except during overhaul.
6. Refer to the Onan engine manual for engine maintenance and troubleshooting instructions.
7. Periodically check the battery water level.

What are the instructions for commutator and brush maintenance on the Lincwelder 225?

The generator brushes are properly adjusted when the welder is shipped. They require no particular attention. DO NOT SHIFT THE BRUSHES or adjust the rocker setting. Periodically inspect the commutator and brushes by removing the commutator cover. DO NOT remove or replace this cover while the machine is running. Commutators require little attention. However, if they are black or appear uneven, have them cleaned by an experienced maintenance man using fine sandpaper or a commutator stone. Never use emery cloth or paper for this purpose. Replace brushes when they wear within ¼" of the pigtail. A complete set of replacement brushes should be kept on hand. Lincoln brushes have a curved face to fit the commutator. Have an experienced maintenance man seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact is made across the full face of the brushes. After stoning, blow out the dust with low pressure air.

What safety precautions should be taken when working with rotating equipment?

Uncovered rotating equipment can be dangerous. Use care so your hands, hair, clothing or tools do not catch in the rotating parts. Protect yourself from particles that may be thrown out by the rotating armature when stoning the commutator.

How do I maintain the rotor slip rings and brushes on the Lincwelder 225?

The rotor slip rings and brushes are virtually maintenance free. Brushes should be changed only during overhaul by a trained mechanic.

What is the Lincoln Exchange Plan?

The LINCOLN EXCHANGE PLAN gives you fast repairs at modest cost. Here’s how: Factory remanufactured replacements for the major parts indicated by + are available. These exchange parts are available only through the local authorized Field Service Shops. To get your welder back into operation quickly, replace the faulty part with a rebuilt part – often from the service shop’s stock. The cost is less than a normal rewinding job. The service shop will ship the removed part to the factory for inspection. If it can be rebuilt, a credit will be issued to the shop. They, in turn, will pass this credit to you, thus further reducing the net cost of the repair. And all exchange parts carry the same one year guarantee as new welders. For more information, contact your local Lincoln authorized Field Service Shop.