Service Manual Lincoln Weldanpower 225
I recently Picked up a nice Lincoln Weldanpower 225 model AC225/DC210/6 its the one with the 16hp Cast iron Briggs I/C one lung engine. The machine is in great shape, It runs excellent welds nice but the battery is not charging and it has no other means of starting it. From what I can tell on the schematics It is supposed to have a flywheel alternator on the engine that provides power to charge the battery and excite the generator.
There are NO wires coming from behind the flywheel at all just the engines magnetron magneto above the flywheel. The Rectifier is present the battery charging board is present everything looks complete and untouched.
There is a wire running from the positive battery terminal to a toggle switch that excites the generator as the generator does not have an exciter. Any suggestions? Is it worth trying to find and replace the flywheel alternator if I can still find one? Its a 326437 engine Thanks.
Okay, so I'm betting that you can find your way around a Briggs. The engines used in welder-generators typically aren't that much different from a standard engine, with exception that some are started using the generator's exciter winding, but IIRC your Weldanpower has a ring-gear starter. The other difference, is that since the prime mover is running a generator/welder, it's not unusual for the welder's generating system to be used to provide battery charging. Since it's already generating in the first place. Sometimes, the excitation circuit wiring not only builds excitation, it also flows in the opposite direction to charge the battery. The B&S parts breakdown suggests something like 5 different charging stators, where several use a dual-output (one for regulated battery charging, the other for unregulated lighting), and others are just charging coils.
Sometimes an external regulator unit is required, other times, the regulation electronics (being fairly minimal) are integrated into the stator assembly. Typically, the stator assembly is NOT physically included with the ignition coil assembly, as the stator would usually be on the inner radius, ignition on the outer, but you probably know these better than I.
In any event, Miller's document on the welder-generator would be the best resource. For some reason, I'm unable to download the Miller manual, but you can find the page here: And the document would most likely be this: There's usually a schematic diagram, it would identify what you're facing in terms of wiring. By your description of the excitation circuit switch, it kinda sounds like something failed in the past, and someone cobbled in a simple fix, and in doing so, probably figured it was easier to just put a battery charger on the unit every so often than devote any resources to making the charging circuit work. With an electronic Magnetron system, no battery is required to get ignition power, so all they needed the battery for was to crank the engine over and provide a moment of excitation. For what it's worth, I have a similar situation with the Miller Bobcat in my service truck- it's battery charging system is inoperative.
SERVICE MANUAL. Turning the engine or welding generator during maintenance. Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio. IM-225 Zenith Carburetor Types: S-8082, S-8318.
It's an old unit, the lower chassis rusted out many years ago, fracturing the fuel tank, so I hoisted it up, removed the original sheet metal chassis, and fabricated a new frame, eliminated the fuel tank and battery (made more clearance under it for better cooling, and allows me to store long pieces of steel under it). The generating output is connected to a load center on my truck, which includes a battery charger to charge a much larger battery for running my service body's lighting, a 500w inverter (charging power tools, running an LED trouble light, etc), and of course, cranking the generator. And I remote-mounted a different (larger) fuel tank elsewhere under the truck. I like it better than the original arrangement. Okay, so I'm betting that you can find your way around a Briggs.
Weldanpower 225 Parts
The engines used in welder-generators typically aren't that much different from a standard engine, with exception that some are started using the generator's exciter winding, but IIRC your Weldanpower has a ring-gear starter. The other difference, is that since the prime mover is running a generator/welder, it's not unusual for the welder's generating system to be used to provide battery charging. Since it's already generating in the first place. Sometimes, the excitation circuit wiring not only builds excitation, it also flows in the opposite direction to charge the battery. The B&S parts breakdown suggests something like 5 different charging stators, where several use a dual-output (one for regulated battery charging, the other for unregulated lighting), and others are just charging coils.
Sometimes an external regulator unit is required, other times, the regulation electronics (being fairly minimal) are integrated into the stator assembly. Typically, the stator assembly is NOT physically included with the ignition coil assembly, as the stator would usually be on the inner radius, ignition on the outer, but you probably know these better than I. In any event, Miller's document on the welder-generator would be the best resource.
For some reason, I'm unable to download the Miller manual, but you can find the page here: And the document would most likely be this: There's usually a schematic diagram, it would identify what you're facing in terms of wiring. By your description of the excitation circuit switch, it kinda sounds like something failed in the past, and someone cobbled in a simple fix, and in doing so, probably figured it was easier to just put a battery charger on the unit every so often than devote any resources to making the charging circuit work. With an electronic Magnetron system, no battery is required to get ignition power, so all they needed the battery for was to crank the engine over and provide a moment of excitation.
Thanks for your reply, I understand how magnetron ignition functions I have also been on Lincolns website and gone through the PDF manuals and diagrams for my machine they show no part numbers and aside from the schematic showing the engines flywheel charging coil being wired into the generator their is no other mention of one or any part numbers for one. I guess for now best I can do is get a Deepcycle battery and keep charging it. I have also thought of adding the flywheel alternator and regulator on and making a separate charging system for the battery not using the welders existing circuitry. You didn't say, so I'm going to ask: Does the battery not crank your engine after prolonged downtime? Does it restart well after it's been run? Have you checked the voltages at the battery terminals?
I ask because, sometimes, a diode will fail. The system will charge the battery while the engine is running but will, also, put a slow draw on the battery when the engine is stopped. I have a single cylinder Tecumseh on my Miller that acts this way. I can restart the engine as many times as I need to during the day. My welder will sit idle for weeks at a time and the battery will be nearly dead when I come to use the machine. I have been taking a cable off the battery when I'm done with the welder and it has started every time.
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You are currently viewing as a guest which gives you limited access to view discussions To gain full access to our community you must; for a free account. As a registered member you will be able to:. Participate in over a dozen different forum sections and search/browse from nearly a million posts. Post photos, respond to polls and access other special features All this and much more is available to you absolutely free when you; for an account, so today! If you have any problems with the registration process or your account login, please. I traded a tow behind mower for this nice lincoln weldanpower 225. It is a code #9175 with an onan engine and has the CV option.
The machine starts and runs very nice. It welds very nice as well, but it will not idle down. It comes up on a rev and just stays there. The only thing I have done is to replace the battery. The old one would not start the machine.
I was able to jumpstart the machine fine, but as soon as I removed the jumper cables the machine turned off. I did find and print out the manual from the lincoln website and am going to look into this problem tomorrow, but figured some one here may have some advice. Congrats on the 'new' machine and the CV option is a definite plus.
The first thing to do on the idler issue is to test the idler solenoid to see if it works by applying 12VDC to its leads. If it doesn't pull in with 12VDC applied, there's your problem. If it does, then the problem is likely the idler control board.
If so, the best thing to do is contact Lincoln Customer Service with the unit SN and request they email you the specific machine wiring diagram and the same for the correct idler board so you can troubleshoot it. Politely explain the issue making your request and they should be more than happy to send you the information in.pdf file format as they have for scores of others in the past. The reason to request the specific diagrams for your unit is due to the fact the W&P 225 went thru a number of controls revisions over the years and without the correct information to refer to you could be chasing your tail in any troubleshooting efforts. Thanks for the information. I traced out all the wires and did find the problem.
The solenoid was not getting 12v because there was a broken connection in the ground going to it. I think that was the wire coming from 215 off of the idler board. Once that was done, she idles up and down just as she should. So far, I really like this machine. It is a very smooth runner.
I think I may have to replace the starter because about 25% of the time, it just spins and does not engage. I'll get some pictures of it today and post them this evening. Today, I am going to change the plugs, change the oil and filter, drain and refill the gas tank with good fuel and wax the case.oh, and burn some rod! Thanks again for the help, wR. One more question (yeah right) regarding this weldanpower.
I am going to be looking to run my Miller Passport off of the 220v side of the generator. There are two problems I see with that right now. 1) the receptacles on the weldanpower are not the correct type 2) the weldanpower says not to draw more than 15A from each 220 receptacle. I am pretty sure I can go ahead and make a new faceplate and replace the receptacle, but I need to be able to draw 20A. Can I re-wire it to safely be able to draw 20A from the 220 side of this generator?
Thanks again. On my WP I believe you can pull 15 amps of 1 of the 220 plugs or a total of 26 amps off both, I made a 2 into 1 feed, ( make sure you phase it properly) and I now run 1 adapter plug from both outlets and run my 150 amp MM120 MIG in the field. I have used it on a couple occasions with no ill effects.
Make sure you plug it in before starting the machine as once you plug one male in, the other male will go hot, sure this is not and OSHA compliant device but use common sense, would be better to feed and additional plug by wiring in direct obviously. Last edited by kolot; at 03:03 PM.