Lincoln Electric Weldmark 225 Mode d'emploi
- Catégorie
- Système de soudage
- Taper
- Mode d'emploi
WELDMARK 225
OPERATOR’ S MANUAL
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. DO NOT I NSTAL L ,
OPERATE OR REPAI R THI S
EQUI PMENT WI THOUT READ-
I NG THI S MANUAL AND THE
SAFETY PRECAUTI ONS CON-
TAI NED THROUGHOUT. And,
most importantly, think before you
act and be careful.
R
R
• 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
Copyright © 2007 Lincoln Global Inc.
C US
WELDMARK 225
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Specications and availability of optional
features may have changed.
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz-
ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
i
SAFETY
i
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.
WARNING
Mar ‘95
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines
The Above For Gasoline Engines
WELDMARK 225
ii
SAFETY
ii
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
WELDMARK 225
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
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
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
iii
SAFETY
iii
WELDMARK 225
Jan, 07
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
though
they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation
for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and folllow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
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 électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
vv
T h a n k
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 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.
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
CAUTION
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.
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
vi
vi
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions ........................................................................................................A-2
Machine Grounding.......................................................................................................A-2
Spark Arrester ...............................................................................................................A-2
Towing...........................................................................................................................A-2
Vehicle Mounting...........................................................................................................A-3
Pre-Operation Engine Service..............................................................................................A-3
Fuel, Oil.........................................................................................................................A-3
Battery Connections......................................................................................................A-3
Welding Output Cables .................................................................................................A-3
Angle of Operation ........................................................................................................A-4
Lifting.............................................................................................................................A-4
High Altitude Operation .................................................................................................A-4
Location and Ventilation................................................................................................A-5
Stacking ........................................................................................................................A-5
Connection of Wire Feeders .........................................................................................A-5
Connection of Tig Module .............................................................................................A-5
Additional Safety Precautions .......................................................................................A-5
Welding Operation, Auxiliary Power Receptacles, and Plugs .............................................A-6
Motor Starting and Extension Cord Length Table ................................................................A-6
Electrical Device Used with the Weldmark 225....................................................................A-7
Auxiliary Power While Welding, Standby Power Connections ............................................A-8
Premises Wiring ...................................................................................................................A-9
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
General Description..............................................................................................................B-1
Welder Controls Function and Operation .............................................................................B-1
Polarity, Range and Control Switch......................................................................................B-2
Start in/Shutdown Instructions.....................................................................................................B-3
Starting the Engine........................................................................................................B-3
Safety Precautions ........................................................................................................B-3
Stopping the Engine......................................................................................................B-3
Break-In Period .............................................................................................................B-3
Welding Process ..................................................................................................................B-4
Stick (Constant Current) Welding..................................................................................B-4
TIG (Constant Current) Welding ..................................................................................B-4
Wire Feed Welding Processes (Constant Voltage)......................................................B-4
Arc Gouging ..................................................................................................................B-4
Summary of Welding Processes ...................................................................................B-5
________________________________________________________________________________
Accessories ........................................................................................................Section C
Optional Equipment...............................................................................................C-1
Recommended Equipment....................................................................................C-2
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Engine Maintenance, Engine Oil Change, Oil Refill Capacities...............D-1
Oil Filter Change....................................................................................................D-2
Overspeed Is Hazardous, Slip Rings.....................................................................D-3
Battery Maintenance, Hardware .....................................................................D-3
Engine Maintenance Parts..............................................................................D-3
________________________________________________________________________
Troubleshooting..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide...................................................................................E-2, E-3
________________________________________________________________________
Wiring Diagrams & Dimension Print..............................................................Section F
Wiring and Connection Diagrams....................................................................F-1,F-2
Dimension Print.......................................................................................................F3
________________________________________________________________________
Parts List.................................................................................................................P-500
________________________________________________________________________
A-1
INSTALLATION
WELDMARK 225
A-1
WELDMARK 225
TECHNICAL SPECIFICATIONS - Weldmark 225 (K2239-4 )
INPUT - GASOLINE ENGINE
RATED 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
RATED OUTPUT @ 104°F (40°C) FOR GENERATOR
Welding Output
AC Constant Current 225A / 25V / 100%
DC Constant Current 210A / 25V / 100%
DC Constant Voltage 200A / 20V / 100%
Auxiliary Power
1
10,500 Watts Peak, 60 Hz AC
9,000 Watts Continuous, 60 Hz AC
120/240 Volts
PHYSICAL DIMENSIONS
Make/Model
Kohler
CH23S
Description
2 cylinder
4 Cycle
Air-Cooled
Gasoline
Engine.
Aluminum Alloy
with Cast Iron
Liners,
Electronic
Ignition
Operating
Speed (RPM)
High Idle 3700
Full Load 3500
Low Idle 2200
Displacement
cu. in.
(cu.cm.)
41(674)
Kohler
Capacities
Fuel:
9 Gal (34 L)
Lubricating Oil:
2.0 Qts. (1.9 L)
Horsepower
23 HP @
3600 RPM
(Kohler)
Starting
System
12VDC
Battery
Electric Start
Group 58
Battery
(435 cold
Cranking
Amps)
1. Output rating in watts is equivalent to volt - amperes at unity factor. Output voltage is within +/-10% at all loads up to rated capacity.
When welding available auxiliary power will be reduced.
A-2
INSTALLATION
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 this engine driven welder supplies
power must:
• be grounded to the frame of the welder using a
grounded type plug, or be double insulated.
Do not ground the machine to a pipe that carries
explosive or combustible material.
------------------------------------------------------------------------
When this welder is mounted on a truck or trailer, its
frame must be electrically bonded to the metal frame
of the vehicle. Use a #8 or larger copper wire connect-
ed between the machine grounding stud and the
frame of the vehicle.
Where this engine driven welder is connected to
premises wiring such as that in your home or shop, its
frame must be connected to the system earth ground.
See further connection instructions in the section enti-
tled “Standby Power Connections”, as well as the arti-
cle on grounding in the latest National Electrical Code
and the local code.
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 insulat-
ed 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. A machine grounding
stud marked with the symbol is provided on the
front of the welder.
SPARK ARRESTER
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 muffler included with this welder does
not qualify as a spark arrester. When required by local
regulations, the K894-1 spark arrester must be
installed and properly maintained.
An incorrect arrester may lead to damage to the
engine or adversely affect performance.
------------------------------------------------------------------------
TOWING
The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle
(1)
is
Lincoln’s K957-1. If the user adapts a non-Lincoln
trailer, he must assume responsibility that the method
of attachment and usage does not result in a safety
hazard nor damage the welding equipment. Some of
the factors to be considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
CAUTION
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
front of this operator’s manual.
-----------------------------------------------------------
WARNING
WARNING
WELDMARK 225
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, state and local laws
(1)
(1) Consult applicable federal, state and local laws regarding specific
requirements for use on public highways.
PRE-OPERATION SERVICE
READ the engine operating and maintenance
instructions supplied with this machine.
A-3
INSTALLATION
A-3
CAUTION
WELDMARK 225
FUEL
Fill the fuel tank with clean, fresh, lead-free gasoline.
Observe fuel gauge while filling to prevent overfilling.
OIL
The Weldmark 225 is shipped with the engine
crankcase filled with SAE 10W-30 oil. Check the oil
level before starting the engine. If it is not up to the full
mark on the dip stick, add oil as required. Make cer-
tain that the oil filler cap is tightened securely. Refer to
the engine Owner’s Manual for specific oil recommen-
dations.
BATTERY CONNECTIONS
Use caution as the electrolyte is a strong
acid that can burn skin and damage eyes.
-----------------------------------------------------------------------
This welder is shipped with the negative battery cable
disconnected. Make sure that the Engine Switch is in
the “STOP” position and attach the disconnected
cable securely to the negative battery terminal before
attempting to operate the machine. If the battery is
discharged and does not have enough power to start
the engine, see the battery charging instructions in the
Battery section.
NOTE: This machine is furnished with a wet charged
battery; if unused for several months, the battery may
require a booster charge. Be careful to charge the bat-
tery with the correct polarity.
LUBRICATION SYSTEM CAPACITY
(INCLUDING FILTER)
Kohler CH23S - 2.0 Quarts (1.9 Liters)
• Damage to the fuel tank may cause
fire or explosion. Do not drill holes
in the WELDMARK 225 base or weld
to WELDMARK 225 base.
WARNING
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away from
tank.
• Do not leave unattended while
fueling.
• Wipe up spilled fuel and allow
fumes to clear before starting
engine.
• Do not overfill tank, fuel expan-
sion may cause overflow.
GASOLINE FUEL ONLY
------------------------------------------------------------------------
WARNING
GASOLINE
can cause fire
or explosion.
VEHICLE MOUNTING
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
• Only transport this Equipment on serviceable
vehicles which are rated and designed for such
loads.
• Distribute, balance and secure loads so vehicle
is stable under conditions of use.
• Do not exceed maximum rated loads for compo-
nents such as suspension, axles and tires.
• Use appropriate nuts bolts and lockwashers to
attach the equipment base to the metal bed or
frame of vehicle.
• Follow vehicle manufacturer’s instructions.
------------------------------------------------------------------------
CAUTION
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.
Listed below are copper cable sizes recommended for
the rated current and duty cycle. Lengths stipulated
are the distance from the welder to work and back to
the welder again. Cable sizes are increased for
greater lengths primarily for the purpose of minimizing
cable voltage drop.
ANGLE OF OPERATION
Internal combustion engines are designed to run in a
level condition which is where the optimum perfor-
mance is achieved. The maximum angle of operation
for the engine is 15 degrees from horizontal in any
direction. If the engine is to be operated at an angle,
provisions must be made for checking and maintain-
ing the oil at the normal (FULL) oil capacity in the
crankcase in a level condition.
When operating at an angle, the effective fuel capacity
will be slightly less than the specified 9 gallons.
LIFTING
The WELDMARK 225 weighs approximately 575
lbs.(261Kg) with a full tank of gasoline. A lift bail is
mounted to the machine and should always be used
when lifting machine. (Do not use lift bail if heavy
accessory or trailer attached-see warning).
A-4
INSTALLATION
A-4
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
0-100 Ft.
(0-30.5m)
100-200 Ft.
(30.5-60.9m)
200-250 Ft.
(60.9-76.2m)
225 Amps
100% Duty Cycle
1 AWG
1 AWG
1/0 AWG
HIGH ALTITUDE OPERATION
At higher altitudes, Welder output de-rating may be neces-
sary.
For maximum rating, de-rate the welder output 3.5% for
every 1000ft. (305m) above 3000ft. (914m).
If operation will consistently be at altitudes above 5,000 ft.
(1525m), a carburetor jet designed for high altitudes should
be installed. This will result in better fuel economy, cleaner
exhaust and longer spark plug life. It will not give increased
power. Contact your local authorized engine service shop
for high altitude jet kits that are available from the engine
manufacturer.
Do not operate with a high altitude jet installed at alti-
tudes below 5000 ft. This will result in the engine run-
ning too lean and result in higher engine operating
temperatures which can shorten engine life.
-----------------------------------------------------------------------
Muffler Relocation
•
Shut off welder and allow muffler to cool before
touching muffler.
-----------------------------------------------------------------------
The WELDMARK 225 is shipped with the exhaust
coming out on the left side. The exhaust can be
changed to the opposite side by removing the two
screws that hold the exhaust port cover in place and
installing the cover on the opposite side. (Operating
the WELDMARK 225 without the cover in place will
result in a higher noise level and no increase in
machine output.)
CAUTION
WARNING
WELDMARK 225
• Lift only with equipment of
adequate lifting capacity.
• Be sure machine is stable
when lifting.
• Do not lift this machine using
lift bail if it is equipped with a
heavy accessory such as trail-
er or gas cylinder.
FALLING • Do not lift machine if lift bail is
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bail.
------------------------------------------------------------------------
WARNING
A-5
INSTALLATION
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 WELDMARK 225
• Shut the welder off.
•
Connect the electrode cable from the LN-25 to
the
“ELECTRODE” terminal of the welder.
Connect the work cable to the “TO WORK” termi-
nal of the welder.
• Position the welder “Polarity” switch to the desired
polarity, either DC (-) or DC (+).
• Position the “RANGE” switch to the “WIRE FEED”
position.
• Attach the single lead from the LN-25 control box
to the work using the spring clip on the end of the
lead - it carries no welding current.
• Place the engine switch in the “AUTO” position.
• Adjust wire feed speed at the LN-25 and adjust
the welding voltage with the output “CONTROL”
at the welder.
NOTE: The welding electrode is energized at all
times, unless an LN-25 with built-in contactor is used.
If the output “CONTROL” is set below “3”, the LN-25
contactor may not pull in.
CONNECTION OF K930-2 TIG MODULE TO THE
WELDMARK 225.
The TIG Module is an accessory that provides high
frequency and shielding gas control for AC and DC
GTAW (TIG) welding. See IM528 supplied with the
TIG Module for installation instructions.
Note: The TIG Module does not require the use of a
high frequency bypass capacitor. However, if the
WELDMARK 225 is used with any other high frequen-
cy equipment, the bypass capacitor must be installed,
order kit T12246.
INSTRUCTIONS
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the roof and case
sides in place as this provides maximum protection
from moving parts and assures proper cooling air flow.
Read and understand all Safety Precautions before
operating this machine. Always follow these and any
other safety procedures included in this manual and in
the Engine Owner’s Manual.
WELDMARK 225
LOCATION / VENTILATION
The welder should be located to provide an unrestrict-
ed flow of clean, cool air to the cooling air inlets and to
avoid heated air coming out of the welder recirculating
back to the cooling air inlet. Also, locate the welder so
that engine exhaust fumes are properly vented to an
outside area.
STACKING
WELDMARK 225 machines cannot be stacked.
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
Shut off welder before making any electrical
connections.
------------------------------------------------------------------------
WIRE FEED (CONSTANT VOLTAGE)
CONNECTION OF LN-15 ACROSS-THE-ARC WIRE
FEEDER
The LN-15 has an internal contactor and the electrode
is not energized until the gun trigger is closed. When
the gun trigger is closed the wire will begin to feed
and the welding process is started.
a. Shut the welder off.
b. Set the Polarity switch to the desired polarity,
either DC (-) or DC (+).
c. Attach the single lead from the front of the LN-15
to work using the spring clip at the end of the lead.
This is a control lead to supply current to the wire
feeder motor; it does not carry welding current.
d. Set the “RANGE” switch to the “WIRE FEED-CV”
position.
WARNING
DO NOT MOUNT OVER COMBUSTIBLE SUR-
FACES.
Where there is a combustible surface directly
under stationary or fixed electrical equipment, the
surface shall be covered with a steel plate at least
.06”(1.6mm) thick, which shall extend not more
than 5.90”(150mm) beyond the equipment on all
sides.
------------------------------------------------------------------------
CAUTION
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 motors can be started if
there is no load on the motor or other load connected
to the machine, since the full load current rating of a
1.5 hp motor is approximately 20 amperes (10
amperes for 240 volt motors). The motor may be run
at full load when plugged into only one side of the
duplex receptacle. Larger motors through 2 hp can be
run provided the receptacle rating as previously stated
is not exceeded. This may necessitate 240V operation
only.
GND
120 V
120 V*
240 V
*Current Sensing for Automatic Idle.
(Receptacle viewed from front of Machine)
GND
120 V
120 V*
240 V
*Current Sensing for Automatic Idle.
(Receptacle viewed from front of Machine)
WELDMARK 225 Extension Cord Length Recommendations
(Use the shortest length extension cord possible sized per the following table.)
Current
(Amps)
15
20
15
20
38
Voltage
Volts
120
120
240
240
240
Load
(Watts)
1800
2400
3600
4800
9000
30
60
(9)
(18)
40
30
75
60
(12)
(9)
(23)
(18)
75
50
150
100
50
(23)
(15)
(46)
(30)
(15)
125
88
225
175
90
(38)
(27)
(69)
(53)
(27)
175
138
350
275
150
(53)
(42)
(107)
(84)
(46)
300
225
600
450
225
(91)
(69)
(183)
(137)
(69)
Maximum Allowable Cord Length in ft. (m) for Conductor Size
Conductor size is based on maximum 2.0% voltage drop.
14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
A-6
INSTALLATION
A-6
WELDER OPERATION
WELDER OUTPUT
• Maximum Open Circuit Voltage at 3700 RPM is
80 Volts RMS.
• Duty Cycle is the percentage of time the load is
being applied in a 10 minute period. For example, a
60% duty cycle represents 6 minutes of load and 4
minutes of no load in a 10 minute period. Duty
Cycle for the WELDMARK 225 is 100%.
AUXILIARY POWER
The WELDMARK 225 can provide up to 9,000 watts
of 120/240 volts AC, single phase 60Hz power for
continuous use, and up to 10,500 watts of 120/240
volts AC, single phase 60Hz power peak use. The
front of the machine includes three receptacles for
connecting the AC power plugs; one 50 amp 120/240
volt NEMA 14-50R receptacle and two 20 amp 120
volt NEMA 5-20R receptacles. Output voltage is with-
in +/-10% at all loads up to rated capacity. All auxiliary
power is protected by circuit breakers. All auxiliary
power is protected by circuit breakers.
Do not connect any plugs that connect to the
power receptacles in parallel.
-----------------------------------------------------------------------
Start the engine and set the “IDLER” control switch to
the desired operating mode. Set the “CONTROL” to
10. Voltage is now correct at the receptacles for auxil-
iary power.
WELDMARK 225
Constant Current 225 Amps AC @ 25 Volts
210 Amps DC @ 25 Volts
Constant Voltage 200 Amps DC @ 20 Volts
CAUTION
WELDMARK 225
120/240 VOLT DUAL VOLTAGE RECEPTACLE
The 120/240 volt receptacle can supply up to 38 amps
of 240 volt power to a two wire circuit, up to 38 amps
of 120 volts power from each side of a three wire cir-
cuit (up to 76 amps total). Do not connect the 120 volt
circuits in parallel. Current sensing for the automatic
idle feature is only in one leg of the three wire circuit
as shown in the following column.
A-7
INSTALLATION
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. regulation can cause the capaci-
tative elements to fail. Surge
protection, transient protection,
and additional loading is recom-
mended for 100% fail-safe oper-
ation. DO NOT RUN THESE
DEVICES WITHOUT ADDI-
TIONAL RESISTIVE TYPE
LOADS.
Inductive Single-phase induction motors, These devices require large
drills, well pumps, grinders, small current inrush for starting.
refrigerators, weed and hedge Some synchronous motors may
trimmers 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
WELDMARK 225
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected
WELDMARK 225WELDMARK 225
A-8
INSTALLATION
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 must be made by a licensed electri-
cian who can determine how the 120/240V power
can be adapted to the particular installation and
comply with all applicable electrical codes.) The
following information can be used as a guide by
the electrician for most applications (refer also to
the connection diagram shown in Figure 1.)
-------------------------------------------------------------------------
1. Install a double pole, double throw switch between
the power company meter and the premises
disconnect.
Switch rating must be the same or greater than
the customer’s premises disconnect and service
overcurrent protection.
2. Take necessary steps to assure load is limited to
the capacity of the WELDMARK 225 by installing a
38 amp 240V double pole circuit breaker.
Maximum rated load for the 240V auxiliary is 38
amperes. Loading above 38 amperes will reduce
output voltage below the allowable -10% of rated
voltage which may damage appliances or other
motor-driven equipment.
3. Install a 50 amp 120/240V plug (NEMA type 14-50)
to the Double Pole Circuit Breaker using No. 8,
4 conductor cable of the desired length. (The
50 amp 120/240V plug is available in the
optional plug kit.)
4. Plug this cable into the 50 amp 120/240V
receptacle on the WELDMARK 225 case front.
WARNING
AUXILIARY POWER WHILE WELDING
Simultaneous welding and power loads are permitted
by following Table I. The permissible currents shown
assume that current is being drawn from either the
120V or 240V supply (not both at the same time).
Also, the “Output Control” is set at “10” for maximum
auxiliary power.
TABLE I
SIMULTANEOUS WELDING AND POWER
Output Selector Permissible Power Permissible Auxiliary
Setting Watts (Unity Power Current in Amperes
Factor) @ 120V
*-or- @ 240V
Max. Stick or Wire
Feed Setting None 00
145 Stick Setting 3450 32 16
90 Stick Setting 6000 50
** 25
NO WELDING 9000 76
** 38
* Each duplex receptacle is limited to 20 amps.
**Not to exceed 40A per 120VAC branch circuit when
splitting the 240 VAC output.
WELDMARK 225WELDMARK 225
240 Volt
60 Hz.
3-Wire
Service
POWER
COMPANY
METER
240 VOLT
120 VOLT
120 VOLT
LOAD
N
NEUTRAL
BUS
GROUND
P
REMISES
DISCONNECT AND
S
ERVICE
OVERCURRENT
P
ROTECTION
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
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
A
S OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
50 AMP, 120/240 VOLT
RECEPTACLE
240 Volt
60 Hz.
3-Wire
Service
POWER
COMPANY
METER
240 VOLT
120 VOLT
120 VOLT
LOAD
N
NEUTRAL
BUS
GROUND
P
REMISES
DISCONNECT AND
S
ERVICE
OVERCURRENT
P
ROTECTION
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
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
A
S OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
50 AMP, 120/240 VOLT
RECEPTACLE
A-9
INSTALLATION
A-9
Connection of WELDMARK 225 to premises wiring
must be done by a licensed electrician and must
comply with the National Electrical Code and all
other applicable electrical codes.
Figure 1
CONNECTION OF WELDMARK 225 TO PREMISES WIRING
WARNING
WELDMARK 225
WELDMARK 225
WELDER CONTROLS - FUNCTION AND
OPERATION
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 energized.
When in “HIGH IDLE” ( ) position, the engine will
run continuously at high idle.
When in “AUTO IDLE” ( / ) position, the
engine will run continuously and the idler operates as
follows:
• Welding
When the electrode touches the work, the welding
arc is initiated and the engine accelerates to full
speed.
After welding ceases (and no auxiliary power is
being drawn), the engine will return to low idle
after approximately 10 to 14 seconds.
• Auxiliary Power
With the engine running at low idle and auxiliary
power for lights or tools is drawn (approximately
100-150 watts or greater) from the receptacles,
the engine will accelerate to high speed. If no
power is being drawn from the receptacles (and
not welding) for 10-14 seconds, the idler reduces
the engine speed to low idle.
B-1
OPERATION
B-1
SAFETY PRECAUTIONS
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
• Always operate the welder with the hinged door
closed and the side panels in place.
• Read carefully the Safety Precautions page
before operating this machine. Always follow
these and any other safety procedures included
in this manual and in the Engine Instruction
Manual.
------------------------------------------------------------------------
GENERAL DESCRIPTION
The WELDMARK 225 is a twin-cylinder, gasoline dri-
ven, multiprocess arc welder and AC power genera-
tor. It is built in a heavy gauge steel case for durability
on the job site.
WELDMARK 225
“ 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
Provides a fine welding current adjustment within the
Range Switch settings in the STICK mode and weld-
ing voltage control with the Range switch set in the
wire feed mode.
Process Range Setting Current Range
POLARITY SWITCH
Provides three selectable welding polarities:
AC, DC+ & DC-
Never change the Polarity switch setting while
welding. This will damage the switch.
------------------------------------------------------------------------
B-2
OPERATION
B-2
CAUTION
CAUTION
KOHLER
23 H.P. COMMAND
.4 Gallons/Hour
(1.5 Liters/Hour)
.7 Gallons/Hour
(2.8 Liters/Hour)
1.2 Gallons/Hour
(4.6 Liters/Hour)
1.3 Gallons/Hour
(4.9 Liters/Hour)
1.2 Gallons/Hour
(4.5 Liters/Hour)
1.4 Gallons/Hour)
(5.3 Liters/Hour)
Low Idle - No Load
2200 RPM
High Idle - No Load
3700 RPM
AC CC Weld Output
225 Amps @ 25 Volts
DC CC Weld Output
210 Amps @ 25 Volts
DC CV Weld Output
200 Amps @ 20 Volts
Auxiliary Power
9000 Watts
WELDMARK 225 APPROXIMATE FUEL CONSUMPTION
STICK/TIG
(constant current)
(3 range settings)
WIRE FEED
(constant voltage)
(one range setting)
90 Max.
145 Max.
210DC/225AC Max.
15 to 25V
40 to 90 Amps
70 to 145 Amps
120 to 210 (DC) 225(AC)
Up to 200 Amps
WELDMARK 225
B-3
OPERATION
B-3
STARTING/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
when starting the engine; cold, warm or hot.
Turn the engine switch to the “start” position and
crank the engine until it starts. Release the switch as
soon as the engine starts, slowly return the choke
control to the full “in” position (choke open),
and turn the switch to the Auto Idle( / )
position. Do not turn the switch to the “start” position
while the engine is running because this will cause
damage to the ring gear and/or starter motor
After running at high engine speed for 10-14 seconds,
the engine will go to low idle.
Allow the engine to warm up by letting it run at low idle
for a few minutes.
STOPPING THE ENGINE
Remove all welding and auxiliary power loads and
allow engine to run at low idle speed for a few minutes
to cool the engine.
Stop the engine by placing the Engine switch in the
“OFF” position.
A fuel shut off valve is not required on the WELD-
MARK 225 because the fuel tank is mounted below
the engine.
BREAK-IN PERIOD
It is normal for any engine to use a greater amount of
oil until the break-in is accomplished. Check the oil
level twice a day during the break-in period (approxi-
mately 50 running hours).
IMPORTANT: IN ORDER TO ACCOMPLISH THIS
BREAK-IN, THE UNIT SHOULD BE
SUBJECTED TO MODERATE
LOADS, WITHIN THE RATING OF
THE MACHINE. AVOID LONG IDLE
RUNNING PERIODS. REMOVE
LOADS AND ALLOW ENGINE TO
COOL BEFORE SHUTDOWN.
The engine manufacturer’s recommendation for the
running time until the first oil change is as follows:
The oil filter is to be changed at the second oil
change. Refer to the Engine Owner’s Manual for more
information.
• Do not touch electrically live parts
of electrode with skin or wet
clothing.
• Keep flammable material away.
• Insulate yourself from work and
ground. Wear eye, ear, and body
protection.
• Keep your head out of the fumes.
• Use ventilation or exhaust to
remove fumes from breathing zone.
WARNING
WELDMARK 225
KOHLER
CH23S
5 HRS
B-4
OPERATION
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 to the desired polarity. The “RANGE”
switch markings indicate the maximum current for that
range as well as the typical electrode size for that
range. The “OUTPUT” Control provides fine adjust-
ment of the welding current within the select range.
For maximum output within a selected range set the
“OUTPUT” Control at 10. For minimum output within a
selected range set the “OUTPUT” Control at 5. (“OUT-
PUT” Control settings below 5 may reduce arc stabili-
ty) For best overall welding performance set the
“RANGE” Switch to the lowest setting and the OUT-
PUT” Control near the maximum to achieve the
desired welding current.
RANGE SETTING TYPICAL CURRENT RANGE
ELECTRODE SIZE
The WELDMARK 225 can be used with a broad range
of AC and DC stick electrodes. See “Welding Tips 1”
included with the WELDMARK 225 for electrodes
within the rating of this unit and recommended weld-
ing currents of each.
TIG (CONSTANT CURRENT) WELDING
The K930-[ ] TIG Module installed on a Weldmark 225
provides high frequency and shielding gas control for
AC and DC GTAW (TIG) welding processes. The TIG
Module allows full range output control. After flow
time is adjustable from 0 to 55 seconds.
When using the Weldmark 225 for AC TIG welding of
aluminum, the following settings and electrodes are
recommended:
The K930-[ ] TIG Module should be used with the
WELDMARK 225 on high idle to maintain satisfactory
operation. It can be used in the AUTO position but the
delay going to flow idle after welding is ceased will be
increased if the AFTER FLOW CONTROL is set
above 10 seconds.
WIRE FEED WELDING PROCESSES
(CONSTANT VOLTAGE)
The Innershield
®
electrode recommended for use with
the WELDMARK 225 is NR
®
-211-MP. The electrode
sizes and welding ranges that can be used with the
WELDMARK 225 are shown in the following table:
The WELDMARK 225 is recommended for limited
“MIG” welding (GMAW - gas metal arc welding). The
recommended electrodes are .030” and .035” L-50
and L-56. They must be used with a blended shield-
ing gas such as C25 (75% Argon - 25% CO
2
). The
welding ranges that can be used with the WELD-
MARK 225 are shown in the following table:
ARC GOUGING
The Weldmark 225 can be used for limited arc goug-
ing.
Set the Range switch to adjust output current to the
desired level for the gouging electrode being used
according to the ratings in the following table:
Diameter Wire Speed Approximate
(in.) Range In./Min. Current Range
.035 80 - 110 75A to 120A
.045 70 - 130 120A to 170A
.068 40 - 90 125A to 210A
Diameter Wire Speed Approximate
(in.) Range In./Min. Current Range
.030 80 - 110 75A to 120A
.035 70 - 130 120A to 170A
SETTINGS FOR PURE TUNGSTEN
TUNGSTEN RANGE SWITCH APPROXIMATE
DIAMETER (in.) SETTINGS CURRENT RANGE
1/8 90 or 145 80 - 150 Amps
3/32 90 or 145 45 - 130 Amps
1/16 90 40 - 80 Amps
SETTINGS FOR 1% THORIATED TUNGSTEN
TUNGSTEN RANGE SWITCH APPROXIMATE
DIAMETER (in.) SETTINGS CURRENT RANGE
1/8 90, 145, or 210 80 - 225 Amps
3/32 90 or 145 50 - 180 Amps
1/16 90 or 145 45 - 120 Amps
ELECTRODE DIAMETER CURRENT RANGE (DC, electrode positive)
1/8 60 - 90 Amps
5/32 90 - 150 Amps
3/16 200 - 250 Amps
90 MAX.
125 MAX.
210(DC)/225(AC)
MAX.
3/32
1/8
5/32
40 TO 90 AMPS
70 TO 145 AMPS
120 TO 210(DC),
225(AC) AMPS
WELDMARK 225
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Lincoln Electric Weldmark 225 Mode d'emploi
- Catégorie
- Système de soudage
- Taper
- Mode d'emploi
dans d''autres langues
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