Lincoln Electric PERKINS SA-250 User's Manual
Contents
1. National Electrical Code lists a number of alternate means of grounding electrical equipment Lift Bail A lift bail is provided for lifting with a hoist A WARNING WR FALLING EQUIPMENT can cause injury e Do not lift this machine using lift bail if it is equipped with a heavy accessory such as a trailer or gas cylinder e Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting Trailers See Optional Features 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 dam age 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 PRE OPERATION INSTALLATION Safety Precautions WARNING 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 H ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground e Always wear dry insulating gloves ENGINE EXHAUST can k2. RET POUR LES MACHINES SOUDER partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde Parc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes LINCOLN V V for selecting a QUALITY product by Lincoln Electric
3. chased locally Ether starting should only be used as required since indiscriminate application will contribute to shortened engine life Available for field installation only Hi Freq K799 Provides high frequency plus gas valve for DC TIG welding Request Publication E385 Optional field installed water valve kit available Order K844 Linc Thaw L2964 5 Control Unit Includes meter and fuses to protect welder when thawing frozen water pipes A WARNING Pipe Thawing IS NOT a CSA approved procedure If not done properly it can result in fire explosion damage to wiring which may make it unsafe dam age to pipes burning up the welder or other haz ards Do not use a welder to thaw pipe before reviewing Lincoln Bulletin E695 1 dated October 1987 or later Mufflers Mufflers are standard on the SA 250 Perkins SPECIFICATIONS Machine Product Ordering 1 Description Rated DC Output 2 Current Range Auxiliary Dimensions amp Weight Name Information Amps Volts Duty Cycle Rd Power HxWxL K1283 4 250 Amp DC ne WFM Arc Welder Perkins Field NS ield Installed Stick DC TIG ne ce 160 240 115 230V Welding 120 190 60 Hz 1650 lbs K1283 5 NEMA Rating 80 130 742 5 kg WEM Min 90 Factory Pure DC Power Ss Se Installed Generator o Duty Cycle Lincoln Rating 40 325 Amps 3 kVA 43 1 x 28 x 67 in 250A 40V 1096 x 711 x 1702 mm 1 WFM Wire Feed Module 2 Bas
4. EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN O Japanese it ies BR Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se 31351300 das partes moventes e N o opere com os paineis abertos ou guardas removidas 0 1 2 211 2 EE 6 CRRRIARRARS SER Ro exo Yel HAE AHSA DRAS gal D L t Aale Cut Al ll e Turn power off before servicing e Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten e N o opere com as tampas removidas O Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas SOX FILA Y ERKE
5. MASA HA HAR o L guet AAL Af d LINCOLN World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
6. We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you 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 Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above 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 CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page GENERAL DESCRIPTION 0 ia Ad td 7 DESIGN SUMMARY oti
7. gt position the idler operates as follows a When welding or drawing power for lights or tools approximately 100 150 watts minimum from the receptacles the engine operates at full speed b When welding ceases or the power load is turned off a preset time delay of about 15 sec onds starts This time delay cannot be adjust ed c If the welding or power load is not re started before the end of the time delay the idler reduces the engine to low idle speed WELDER OPERATION A WARNING A Q ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground FUMES amp GASES can be dangerous Keep your head out of the fumes e Use ventilation or exhaust to remove fumes from breathing zone De TC WELDING SPARKS can cause fire or explosion e Keep flammable material away ARC RAYS can burn Wear eye ear and body protection E NS Duty Cycle The NEMA output rating of the SA 250 is 250 amperes at 30 1 arc volts on a 60 duty cycle Duty cycle is based on a ten minute period thus the welder can be loaded at rated output for six minutes out of every ten minute period 1 The Lincoln plus output rating at 60 duty cycle is 250 amperes at 40 volts Control of Welding Current CAUTION DO NOT TURN THE CURRENT RANGE SELEC TOR WHILE WELDING because the current may arc between th
8. oil should be acceptable for most typical ambient temper atures Consult the engine operation manual for spe cific engine manufacturer s recommendations Upon receipt of the welder check the engine dipstick to be sure the oil is at the full mark DO NOT OVERFILL Fuel Fill the fuel tank with the grade of fuel recommended in the Engine Operator s Manual Make sure the fuel valve on the sediment bowl is in the open position Cooling System The cooling system has been filled at the factory with a 50 50 mixture of ethylene glycol antifreeze and water Check the radiator level and add a 50 50 solu tion as needed See engine manual or antifreeze container from alternate antifreeze recommendation Cold Weather Starting When overnight tempera tures are between 10 F 12 C and freezing use the standard Thermostart starting system installed on all engines Follow the instructions on the nameplate and in the engine manual shipped with the welder With fully charged batteries and the proper weight oil the Thermostart system operates satisfactorily even down to about 0 F 18 C If the engine must be frequently started below 107 12 C it may be desirable to remove the Thermostart and install the optional ether starter kit Installation and operating instructions are included in the kit Use ether starting only when required because excessive use shortens engine life Stopping the Perkins D3 152 Engi
9. over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland here is a 10 discount on all orders of 50 00 or more for shipment at one time to one location T TnTnT lorders of 50 or less before discount or orders outside o
10. 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 Also see item 1 c LINCOLN SAFETY PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pin
11. 0 H Educational Video Information incentive Management 186 M __ Bee LA New Approach to industrial Economics 5 00 NA lames F Lincoln Arc Welding The American Century of John 66 8 AC NS Welding Preheat Calculator 159 wes Pipe Welding Ohars aso 88 l es SUBTOTAL Rarer ripping 1 tran cost LE A A A veel USE THIS FORM TO ORDER looks OR FREE INFORMATIVE CATALOGS Foundation Book Information JFLF 515 O Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo e Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz e Use protec o para a vista ouvido e corpo B HRUSBCRBRELTE iD RR HRARGHRBAR ex 19 Sal 8 HSSHAR dis due Gl ysl A e Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos RATE U DORMTORRIER 32381 LU THEN EA o 18 12 R ML IF AT LS AS AIX He Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque la
12. 60 seconds wait 30 seconds before repeating the above procedure f Allow the engine to run at high idle speed for sever al minutes to warm up Cold engines tend to run at a speed too slow to supply the voltage required for proper idler operation When a forceful digging arc is required usually for vertical and overhead welding use a higher Current Range Selector setting and lower open circuit volt age For example to obtain 175 amps and a forceful arc set the Current Range Selector to the 240 160 position and the Fine Current Adjustment setting to get 175 amps CAUTION DO NOT attempt to set the Current Range Selector between the five points designated on the nameplate These switches have a spring loaded cam which almost eliminates the possibility of setting this switch between the designated points Idler Operation Start the engine with the Idler Control switch in High Idle position Allow it to run at high idle speed for several minutes to warm the engine The operat ing speeds are as follows ORDERING FULL HIGH LOW INFO LOAD IDLE IDLE K1283 Perkins 1725 1800 1350 ALL Diesel The idler is controlled by an Idler Control toggle switch on the welder control panel The switch has two positions as follows 1 In the High position the idler is off and the engine runs at the high speed controlled by the governor 2 In the Automatic lt
13. D PSB EPERA FE WS 188781577 e Sal Hai SS AHAL Aa AL pil gS e Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a e Use ventilac o e exhaust o para remover fumo da zona respirat ria 5 83 51585 0 F n RBAPHECTIHIEBLTIA D ECETIA OF Bit ADAN A ARE eya 37128 22 7 S XACOER E 2743 MAS AH 72751717 SSI S ABSHIAIS ad Land a O d L LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURAN A DO EMPREGADOR SRM OBO DEREESLIRA ETERLTF O TLTRHOREMEN gt DE EK E E EE RES AMEN EE R D 8 5 ECKE o AZo SEE AAAS RATAS ETA BHE ET
14. H NO s6du SOTA ZAOHZS ONINNGA JON ENIHOVH HLIM Norursoa een A 1 voon 0044 07 ea gt i i f i El i zeen i asc i monza aas RE HOLIMS 872148288 IOBINOD SLOWEY 10833110372 3310110353 1 26 85 8 o annox OLON ONILAVLS 2098 0065 TONINO suen UILINOLINELOS anon LOZA uoa sata IWNOTLdO L zouge Sais aus S ON ON LAVIS ONYAHL AILIN UNOH SNIONG mn R be ABLINOI LAVISONAZHL SH bT 24S asna JE HOLIMS NOILINOI ANTAN NOILOALOYA ANIONX ATSNESSY IVISONEAKL anwy osz vegan 76 DIN OL LOENNOD TWNIWEEL 104100 AD SAi Neen STWNIWEEL 104100 DN Y OL LDENNOD as asma HAM NO Sdu DOTA LOINNOD 8 1015280502 ASAHI ONINVW NAHM ONINNOY F4 LON LSAW ANIHOVN aval Aan Ca avat Auen 74 Tnqon agaa TAIM ANIHOWA NO Er 1012250102 OL HOLDENNOD KOWA sOT a DATA HAONEN ENTHOWH NO STOGOW CAJA JAIM auna NOTLOSCNT ana us E EE anss ua 110 arona1os P HOLIMS ATTI VS 0SE Y 9 57 IWNOILdO HRNAOASNVAL INAYINO 2222322235 LIOA STT ANO SLINO gengen NO sawat NMOYE N NAJAD D EC 8002 80703 65 Lesta aad 59108 8 8 WYYOVId ONTAIM 09 ANY 09 9 AHI NI 08352810005 FUY SAVAT apisul pa3sed si apo 2 0 e 107 6 0 2 2505 SU
15. L enueuu siy Aq p218A02 saulyoeu IS 104 2 aq jou Aew 1 ostet ADWIA ANY den AHL AI mess TIIM ANTHOVA 80 08 7 1001042 SLOWEY 382 76 SIHL NO 48125 42 JON FAY ANY XINO SANIHOYW I DISSWIO NO AISA FAY SAYT YOWTG ANY ATA IHL GRTIVISNI BINGOW gene FAIM Y XO gemeeten 90TA oe ENTHOYH SHE NO ep HOLDENNOD 440 ANTHOVA AHL HLIM RTTVISNI SI 31040 Gaza FEIM ON aT 7 ANIHOVA JHL NO SI BNO aI 04 DOTA 440 ANTHOVA AHL HLIM GRTIVISNI SI WAGON AIHA TUIM W Tx ENIHOWA NO HOLOBNNOD OL LIX TOULNOD ELOMEN NO 440 INIHOVA HEIN x NOILISOS T OOT NI NMOHS TO LNOD Steen HO enen HOLIMS woen sas moraa DE a 0 HOLIMS 87214828 IOBLNOD Sien 1081100 ALONHH 8 648 99 BAILVOEN ANTAN qaqa 2 SONIGNIM KEEN AUWITIXOW HOLVNYBLTY EECH LIOA OEZ NONI OL ISANVAN ONIN 56 SONIA 56 HOLUNAALTV D ILVE NV 3030225 FALNIN ENVIA OL 0301608 6 UVAS HOYA 030317 SY 6 SINANO4NOD TANYA 665 DOTA MAN AHD NILSVA 085531010210 AHL dO 576 er 801225 042 HOJA SNIHOWW NO Ed SATA 3 coco re AHL LOOHLIN geen SI LI dI HOLIMS TOWLNOD SLOWEY SHL OL YNDDO NYO ZOWHYA YOLIENNOD OL LIX TOULNOD FHL WOWA DOTA LOBNNOD HZ NO w0Tdw 9073 6 AT ONTAWET K YVEN wT Taw ed SOTA LOBNNOD NEHL XO YALSMOTINGLOA IOWINOD 85 2 o SLOWEY wos DO
16. LF 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 8 Cutting ANSI Standard 249 17 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 FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 y 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS may be dangerous 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 no
17. SA 250 PERKINS Eh Diesel Engine Driven DC Arc Welding Power Source For use with machines having Code Number 10073 or 10073CV 10074 RETURN TO MAIN MENU 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 thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Date of Purchase Serial Number Code Number Model o o _ 0 Where Purchased OPERATOR S MANUAL LINCOLN E Copyright O 2000 Lincoln Global Inc e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com i SAFETY l A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSE
18. TA IWNOILdO MARLIN A9 3 99 HAILISOd 23618 aval UE TAM Tt es HOLIMS AOLOATES 6a 80 IWLSOSHE se von rel H K n T DIMENSION PRINT 45 07 16 53 lt 42 CENTER OF GRAVITY WITH OIL AND WATER IN ENGINE BUT NO FUEL 3 00 81 DIA HOLES 69 DIA HOLES M8869 24 7 28 95E 28 00 NOTES LINCOLN New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals 700 00 Now Available 12th Edition The Procedure Handbook of Arc Welding With
19. ails to gener ate current C Welding arc is loud and spat ters excessively 1 See FLASHING THE FIELDS on following page TROUBLESHOOTING Continued TROUBLE CAUSE WHAT TO DO D Welding current too great or 1 Exciter output low causing low 1 Check exciter field circuit too small compared to indica output compared to dial indica tion on the dial tion Operating speed too low or high Adjust speed screw on governor for 1800 RPM operating speed E Arc continuously pops out Current Range Selector switch Set the switch at the center of may be set at an intermediate the current range desired position 1 FLASHING THE FIELDS AC Auxiliary Power 1 Stop the engine welder and remove the cover from the exciter 2 Turn the Fine Adjustment Control rheostat to 100 on the dial 3 Using a 12 volt automotive battery connect its negative terminal to the negative brushholder The negative brushholder is the one nearest to the rotor lamination See the wiring diagram With the engine NOT running touch the positive battery terminal to the positive brushholder Remove the battery from the circuit 4 Replace the exciter cover Start the welder and the generator voltage should build up ELECTRONIC IDLER TROUBLESHOOTING GUIDE Engine Will Not Return to Idle in Approximately 15 Seconds Set Idler Control Switch to the Auto Position Check to see Whether Oil Pressure Light is On and Alt
20. ally live parts or electrode with skin or wet clothing e Insulate yourself from work and ground e Always wear dry insulating gloves ENGINE EXHAUST can kill e Use in open well ventilated areas or 2 6 GA vent exhaust outside a MOVING PARTS can injure e Do not operate with doors open or guards off A Stop engine before servicing e Keep away from moving parts See additional warning information at front of this operator s manual General Instructions for Diesel Engine Welders 1 Blow out the welder and controls with an air hose at least once every two months In particularly dirty locations this cleaning may be necessary once a week Use low pressure air to avoid driving dirt into the insulation 2 Current Range Selector contacts should not be greased To keep the contacts clean rotate the current control through its entire range frequently Good practice is to turn the handle from maximum to minimum setting twice each morning before starting to weld Auxiliary Power The AC auxiliary power supplied as a standard has a rating of 3 0 KVA of 115 230V AC 60 Hz With the 3 0 KVA 115 230V AC auxiliary power one duplex 115V grounding type receptacle NEMA con figuration 5 15R is provided For the 230V AC power one grounding type duplex receptacle is pro vided NEMA configuration 6 15R The circuit is pro tected with circuit breakers The rating of 3 0 KVA permits a maximum conti
21. ce une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse 9 Ass
22. d rough ness of surface on which the trailer will be operat ed environmental conditions amp likely maintenance 5 Conformance with federal state and local laws 1 1 Consuit applicable federal state and local laws regarding specific requirements for use on public highways Polarity Control amp Cable Sizes With the engine off connect the electrode and work cables of the appropriate size see the following table to the studs located on the fuel tank mounting rail For Positive polarity connect the electrode cable to the terminal marked Positive For Negative polari ty connect the electrode cable to the Negative stud These connections should be checked periodically and tightened if necessary When welding at a considerable distance from the welder be sure you use ample size welding cables Recommended Copper Cable Sizes 250 Amps 350 Amps 60 Duty Cycle 25 Duty Cycle Up to 200 ft 200 250 ft Battery Charging WARNING yw GASES FROM BATTERY can explode e Keep sparks flame and cigarettes away BATTERY ACID can burn eyes and skin e Wear gloves and eye protection and be careful when boosting charging or working near battery To prevent EXPLOSION when a Installing a new battery disconnect the negative cable from the old battery first and connect the negative cable to the new battery last Connecting a battery charger remove the battery from the weld
23. e contacts and damage the switch The Current Range Selector provides five overlap ping current ranges The Fine Current Adjustment adjusts the current from minimum to maximum within each range Open circuit voltage is also controlled by the Fine Current Adjustment permitting control of the arc characteristics A high open circuit voltage setting provides the soft buttering arc with best resistance to pop outs pre ferred for most welding To get this characteristic set the Current Range Selector to the lowest setting that still provides the current you need and set the Fine Current Adjustment near maximum For example to obtain 175 amps and a soft arc set the Current Range Selector to the 190 120 position and then adjust the Fine Current Adjustment for 175 amps MAINTENANCE 44 WARNING Have qualified personnel do the maintenance work Turn the engine off before working inside the machine In some cases it may be neces sary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is com plete Always use the greatest care when work ing near moving parts Do not put your hands near the engine cooling blower fan If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill Do not touch electric
24. ed on a 10 Minute Period Engine Product Description Horsepower Operating Displacement Capacities Name Speeds Perkins D3 152 3 Cylinder Full Load Full Load 152 Cu in Fuel 4 Cycle 38 2 HP 1725 RPM 2 5 Itrs 15 gals 57 ltrs Water Cooled 1725 RPM Diesel Engine with High Idle Oil Thermostart Glow Plug 1800 RPM 7 2 qts 6 9 ltrs and Engine Protection Low Idle Water 1350 RPM 10 qts 9 5 ltrs Machine Grounding According to the United States National Electrical Code the frame of this portable generator is not required to be grounded and is permitted to serve as the grounding means for cord connected equipment plugged into its receptacle 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 welding generator frame foot If an older portable welder does not have a grounding stud connect the ground wire to an unpainted frame screw or bolt 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 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 U S
25. er to discover varying current This applies to both the main genera tor amp the exciter Tighten all connections Use Lincoln brushes Inspect amp clean the rheostat Be sure that all brushes bear on the commutator and have proper spring tension Check exciter output voltage with voltmeter or lamp Check for open circuits in rheo stat field leads and field coils Check rectifier bridge Flash fields 1 Check circuit with ringer or volt meter Check setting and current output With ammeter Check polarity Try reversing polarity or try an electrode of the opposite polarity TROUBLESHOOTING 1 Rough or dirty commutator Brushes may be worn down to limit Field circuit may have variable resistance connection or inter mittent open circuit due to loose connection or broken wire Electrode lead or work lead con nection may be poor Wrong grade of brushes may have been installed on genera tor Field rheostat may be making poor contact and overheating Generator or exciter brushes may be loose or missing Exciter may not be operating Field circuit of generator or exciter may be open Exciter may have lost excitation Series field and armature circuit may be open circuited Current setting may be too high Polarity may be wrong TROUBLE A Machine fails to hold the heat consistently B Welder starts but f
26. er by disconnecting the negative cable first then the positive cable and battery clamp When reinstalling connect the negative cable last Using a booster connect the positive lead to the battery first then connect the negative lead to the ground lead on the base d oy To prevent ELECTRICAL DAMAGE when Installing a new battery b Using a booster D Use correct polarity Negative Ground To prevent BATTERY DISCHARGE if you have an ignition switch turn it off when engine is not running e To prevent BATTERY BUCKLING tighten nuts on battery clamp until snug The SA 250 is equipped with a wet charged battery The charging current is automatically regulated when the battery is low after starting the engine to a trickle current when the battery is fully charged When replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed The system is NEGATIVE GROUND PRE OPERATION SERVICE A CAUTION READ the engine operating and maintenance instruc tions supplied with this machine A WARNING Fuel can cause fire or explosion e Stop engine while fueling e Do not smoke when fueling e Do not overfill tank e Keep sparks and flame away from tank e Wipe up spilled fuel and allow fumes to clear before starting engine LA Oil This unit is supplied from the factory with the engine crankcase filled with a high quality 10W30 oil This
27. ernator is Charging Light OFF Light ON If Oil Light is O K Replace Check Continuity of Idler Oil Pressure Switch Control Switch y Continuity Good Open y 1 Reed Switch in Weld Replace Switch Circuit may be Stuck Closed Y 2 Check Continuity of Idler Solenoid Coil 25 ohms y 3 Replace P C Board Engine Will Not Pick Up Speed When The Arc is Struck The Auxiliary Power Load is Turned On Reed Switch in Weld Circuit Defective Will Not Close Power Load Too Small Try Load Above 150 Watts To Check Short the Red Lead on P C Board to Welder Frame Engine Does Not Pick Up Speed Replace P C Board Engine Picks Up Engine Does Not Speed When Arc Pick Up Speed is Struck Replace P C Board Replace Reed Switch in Weld Circuit Jaquinu 2 2 juauudinbs y anc 0 e 104 ayy 07 AUM 631 1 S 6 au y Sued aunso us y JO auo UO aulyoeu ayy 1 1 vs ose any AIu0O aussi S 69 06 SIUL OST WS SHL NI 4312810107 FAY SAVAT XDWIA ANY AHL AI IOSIS TIIM ANIHOVA SIHA NO geen ENIHOYH WO ANY TOMINOD 850105 HHL OL SOWHYA JON 28 ANY KINO SANIHOVA I DISSWID NO AISA FUY SAVAT XOVIS ANY gen IHL ANIHOVA NO ver HOLOENNOD OL TO LNOD SLOWEY NO DOTA JDINNOD NAHL 4824 HOLOENNOD WONI ENIHOY
28. f North America must be prepaid with charge check or money order in U S Funds Only l IPrices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery ee Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value up to 49 99 l 10 00 For order value between 50 00 amp 99 99 l 15 00 For order value between 100 00 amp 149 00 I IFor North America invoiced orders over 50 00 8 credit card orders if UPS is requested it will be invoiced or charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment METHOD OF PAYMENT Sorry No C O D Orders Name CHECK ONE Seege I Please Invoice only if order is over 50 00 I Check or Money Order Enclosed U S Funds only I Credit Card a e Telephone Signature as it appears on Charge Card ER No LL LTL LTL exp ate j Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 ILincoin welding Schoo ries Price Code Quantity Cost ED 80 New Lessons in Arc Welding L Information Procedure Handbook Twelfth Edition 15 00 PH How to Read Shop Drawings 45
29. g neen een nenna 17 19 Elashing the Fields 2 ete ose de EE dd sales 19 Electronic Idler Troubleshooting ss 20 WIRING DIAGRAM GA 250 21 DIMENSION PRINT set tica iia 22 PARTS EISTS ik atid a A ines P237 Series P78 D and P25 L Auxiliary Power 3 0 KVA of nominal 115 230V 60 Hz ACT See Optional Features for Power Plug Kits 1 Output voltage is within 10 at all loads up to rated capacity Welder Enclosures The complete welder is rubber mounted on a rugged steel base The output terminals are placed at the side of the machine so that they are protected by the door The output terminals are labeled and Remote Control K924 1 for K1283 4 5 Field Installed Provides a receptacle switch and remote control box with 100 ft cord for fine current and OCV adjustment at the weld ing site Cranking System 12 volt electric starter is standard Air Cleaner Heavy duty two stage dry type Muffler A muffler to reduce engine noise is standard on the diesel engine units Engine Hour Meter A meter to record the hours of operation Diesel Engine Protection The system shuts the engine down in the event of sudden low oil pressure or high coolant temperature GENERAL DESCRIPTION The SA 250 is a heavy duty engine driven DC arc welding power source capable of providing constant current o
30. he electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side AR Connect the work cable to the workpiece as close as possible to the area being welded 1 9 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 Do not work next to welding power source Mar 95 LINCOLN SAFETY d ARC RAYS can burn 4 a Use a shield with the proper filter and cover Lo plates to protect your eyes from sparks and A the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 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 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 3 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 ventilat
31. igned shaft Have an authorized Field Service Shop check and realign the shaft 3 Change the crankcase oil at regular intervals using the proper grade of oil as recommended in the engine operating manual 4 Change the oil filter in accordance with the instruc tions in the engine operator s manual When the filter is changed add a quart of oil to the crankcase to replace the oil held in the filter during operation 5 Inspect the air filter daily more often in dusty con ditions When necessary clean or replace The filter should never be removed while the engine is running 6 Change the diesel fuel filters every 500 hours of operation 7 Fan belts tend to loosen after the first 30 or 40 hours of operation Check and tighten if neces sary DO NOT OVERTIGHTEN 8 Put a drop of oil on the Current Range Selector shaft at least once every month 9 See the engine manufacturer s Operating Manual for detailed engine maintenance and troubleshoot ing instructions Cooling System The SA 250 is equipped with a pressure radiator Keep the radiator cap tight to prevent loss of coolant Clean and flush the cooling system periodically to pre vent clogging the passage and overheating the engine When antifreeze is needed always use the permanent type ORDERING INFORMA COOLING SYSTEM TION CAPACITY K1283 ALL 10 Quarts Bearings This welder is equipped with a double shielded ball bearing having sufficient grease
32. ill e Use in open well ventilated areas or a vent exhaust outside 56 a MOVING PARTS can injure e Do not operate with doors open or guards off S e Stop engine before servicing e Keep away from moving parts 7 See additional warning information at front of this operator s manual Exhaust Spark Arrester Some federal state or local laws may require that diesel 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 a spark arrester When required by local regulations suitable spark arresters must be installed and properly maintained 44 CAUTION Use of an incorrect arrester may lead to engine damage or performance loss Contact the engine manufacturer for specific recommendations Location Ventilation Always operate the welder with the doors closed Leaving the doors open changes the designed air flow and may cause overheating The welder should be located to provide an unrestrict ed flow of clean cool air Also locate the welder so that the engine exhaust fumes are properly vented to an outside area 3 Proper placement of the equipment on the under carriage to ensure 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 spee
33. ion 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 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 products 5 c 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 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 e Also see item 1 b Mar 95 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
34. n circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN CYLINDER may explode SC s 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located e Away from areas where they may be struck or subjected to physical damage eA safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication PI Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY
35. ne a Turn the ignition control to OFF At the end of each day s welding refill the fuel tank to minimize moisture condensation in the tank Also running out of fuel tends to draw dirt into the fuel sys tem Check the crankcase oil and radiator water level ENGINE OPERATION 44 WARNING 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 o e Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground e Always wear dry insulating gloves ENGINE EXHAUST can kill e Use in open well ventilated areas or a vent exhaust outside 8 a MOVING PARTS can injure e Do not operate with doors open or guards off a Stop engine before servicing e Keep away from moving parts See additional warning information at front of this operator s manual Operate the welder with the doors closed Leaving the doors open changes the designed air flow and can cause overheating Starting the Perkins D3 152 Engine a Turn the idler control to HIGH b Turn the ignition control to ON c Push in the RESET button d Press the START button Release button when engine starts e If the engine fails to start in
36. nuous current of 13 amps to be drawn from the 230 volt duplex receptacle Or a total of 26 amps can be drawn from the 115 volt duplex receptacle The 115 volt duplex receptacle has a configuration which per mits 15 amps to be drawn from either half Therefore on this machine up to 15 amps continuous can be drawn from one half and the balance of 11 amps from the other half The total combined load of all recepta cles is not to exceed 3 0 kVA An optional power plug kit is available When this kit is specified the customer is supplied with a plug for each receptacle In this case he will receive two 15 amp 115 volt plugs NEMA configuration 5 15P and two 15 amp 230 volt plugs NEMA configuration 6 15P clean equipment More bearing failures are caused by dirt introduced during greasing than from insuffi cient grease Commutator amp Brushes 44 WARNING 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 rotat ing armature when stoning the commutator 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 Shifting of the brushes may result in change in machine output commutator damage excessive brush wear Periodically inspect the commutator slip rings and bru
37. per operation of the idler requires good ground the nearest Lincoln Field Service Shop ing of the printed circuit board through its mount ing reed switch and battery e ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground e Always wear dry insulating gloves 4 If desired the welder can be used without automat ic idling by setting the Idler Control switch to the High Idle position 5 When installing a new battery or using a jumper battery to start the engine be sure the battery polarity is connected properly The correct polarity is negative ground Damage to the engine alterna f tor and the printed circuit board can result from incorrect connection ENGINE EXHAUST can kill e Use in open well ventilated areas or CA vent exhaust outside a MOVING PARTS can injure e Do not operate with doors open or guards off a Stop engine before servicing e Keep away from moving parts See additional warning information at front of this operator s manual Nameplates Whenever routine maintenance is performed on this machine or at least yearly inspect all nameplates and labels for legibility Replace those which are no longer clear Refer to the parts list for the replace ment item number CAUSE WHAT TO DO 1 Commutator should be turned or cleaned Replace brushes Check field current with ammet
38. powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY 7 WELDING SPARKS can lt gt 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 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 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 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
39. s partes o los electrodos bajo carga con la piel o ropa moja da O Aislese del trabajo y de la tierra O Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e solez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e Nao toque partes el tricas e elec trodos com a pele ou roupa molha da O Isole se da peca e terra REPOR iHe ELE het EE LATE OHLMPT APYORAPHRBS NTWSHRELTFSU DEBREREAR 47 12 77 SR O HATCHA d TH e Sal Siss HS Ey s qe gu BAA e Su AXE HZA ole Je L Gre o El Aal die WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO Japanese ZS BIR Korean READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET
40. shes by removing the covers DO NOT remove or replace these covers while the machine is running Commutators and slip rings 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 NOTE If the welder is used in dirty or dusty locations or if the welder is not used for prolonged periods of time it may be necessary to clean the commutator and slip rings more often Replace brushes when they wear within 1 4 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 mainte nance 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 To seat the slip ring brushes position the brushes in place Then slide one end of a piece of fine sandpa per between slip rings and brushes with the coarse side against the brushes With slight additional finger pressure on top of the brushes pull the sandpaper around the circumference of the rings in direction of rotation only until brushes seat properly In addition stone slip ring with a fine stone Brushes must be seated 100 Arcing or excessive exciter brush wear indicates a possible misal
41. t start engine until fumes have been eliminated 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 Si Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety LZ se minimize exposure to EMF fields from the welding circuit 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 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 1 f Do not put your hands near the engine fan e Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between t
42. tis EE 7 OPTIONAL FEATURES uta ae ra aech ge 8 SPECIFICATIONS estes tie relents pi alae 9 PRE OPERATION INSTALLATION iii 10 11 Safety Precautions aussi ren nt lee a ae TeRi 10 Exhaust Spark Arrester ss 10 Location Ventilation Nee tue traine EEN KE 10 Machine Grounding isc 28 A add AAA 10 Lift E UE 10 Trailers sites ado 10 11 Polarity Control and Cable Gizes 11 PRE OPERATION SERVICE 3228 tte ado eege 12 Oil An me AAA L PQ ae 12 Oe eessen ne Mn A nm ne 12 600111053151611 1 Hk eee ita oe el Rein ele 12 Battery Ch rging 5258 tn a a Rat an rs baat 12 ENGINE OPERATION rocosa nee A a ee dada net tt 13 Starting the Perkins D3 152 Engine oncccccnnnccccconccoconcnnnononn nono nnnnn cnn rra n nn n nr nnnnn rra 13 Stopping the Perkins D3 152 Engime 13 WELDER OPERATION tea 14 15 RIIT 14 Control of Welding Current dnde dada erat 14 Idler Op ration han nn RO Re HT E 14 Auxiliary POWER de A Hors dre tn 15 MAINTENANCE ebe gehen adas dee ege nr ee dE te 15 17 General Instructions for Diesel Engine Welders 15 Cooling Systm cio min de fe rs die nat et At en Ar do ates 16 ee Lull EE 16 Commutator and Drushes aE A iA 16 Idler Maintenance unie agen age Rai agen angine dae 17 Nameplate sio ad sede aie ee hence 17 TROUBLESHOOTING asii rada edn anes 17 20 Welder Troubleshootin
43. to last indefinitely under normal service Where the welder is used con stantly or in excessively dirty locations it may be nec essary to add one half ounce of grease per year A pad of grease one inch wide one inch long and one inch high weighs approximately one half ounce Over greasing is far worse than insufficient greasing When greasing the bearings keep all dirt out of the area Wipe the fittings completely clean and use Idler Maintenance A CAUTION TROUBLESHOOTING A WARNING Have qualified personnel do the troubleshooting work Turn the engine off before working inside the machine In some cases it may be neces Before doing electrical work on the idler printed circuit board disconnect the battery 1 The solenoid plunger must work freely because sary to remove safety guards to perform binding can cause engine surging If surging required maintenance Remove guards only occurs be sure the plunger is properly lined up when necessary and replace them when the with the throttle lever Dust the plunger about once maintenance requiring their removal is com a year with graphite powder plete Always use the greatest care when work ing near moving parts 2 When any service is done reassemble the rubber bellows on the solenoid plunger with the vent hole Do not put your hands near the engine cooling on the lower side blower fan If a problem cannot be corrected by following the instructions take the machine to 3 Pro
44. trol Switch on the panel locks the idler in full speed position when desired Power Plug Kit K802C e A power plug kit for the auxiliary power receptacles is available Provides a plug for each receptacle Trailer K913 Two wheeled highway trailer with steel torsion bar axle 54 137cm wheel track Low sway low center of gravity Sturdy tread plate platform Choice of 3 hitches Add on fender amp light package For highway use consult applicable local laws regarding possible additional requirements Order K913 1 Base Trailer K913 2 Ball Hitch K913 3 Lunette Eye Hitch K913 4 Clevis Pin Hitch K913 5 Fender amp Light Kit Wire Feed Module K623 1 The Wire Feed Module is field installed on the K1283 4 and factory installed on the K1283 5 to provide CV constant voltage output for semiautomatic welding Output rated at 250 Amps at 35 Volts with a 60 Duty Cycle and 310 Amps at 32 Volts with a 35 Duty Cycle DIMENSIONS See dimension Print M8869 24 at the rear of this man ual OPTIONAL FEATURES Accessory Set K703 Includes electrode and work cables headshield work clamp and electrode holder Ether Start Kit K793 1 for Perkins Engine When frequent starting is expected below 10 F 12 C remove the thermostart system and install the optional ether start kit to provide maximum cold weather starting assistance Note The required ether tank is not provided with the kit and must be pur
45. urer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle PR CAUTIONS DE S
46. utput for stick welding or DC TIG welding With the addition of the optional Wire Feed Module for K1283 4 the SA 250 will provide constant voltage output for running the LN 25 LN 23P or LN 7 wire feeders The Wire Feed Module is factory installed on the K1283 5 SA 250 The SA 250 has a current range of 40 325 DC amps with a 60 duty cycle at 250 amps 40 volts The units are also capable of providing 3 kVA of 115 230 volt 60 Hertz AC auxiliary power DESIGN SUMMARY Control Panel Both the engine and the welder controls are located on one recessed panel at the auxiliary power alterna tor end of the machine The welder controls consist of a five step Current Range Selector switch and a Fine Current Adjustment rheostat Each welder is equipped with a Start button and an Idler Control switch The Perkins diesel uses a Thermostart but ton and has a Stop control On this panel is also mounted an engine temperature gauge a battery charging ammeter an oil pressure gauge and the three prong grounded type auxiliary power receptacle Copper Shunt Windings For long life and dependable operation Engine Idler The SA 250 is equipped with an electronic automatic engine idler It automatically increases and decreases engine speed when starting and stopping welder or using auxiliary power A built in time delay permits changing electrodes before the engine slows to its low idle speed The Idler Con
47. 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the ope
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