Lincoln Electric PERKINS 350-SA User's Manual
Contents
1. 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 Alternator 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 y 1 Reed Switch in Weld Replace Switch Circuit may be Stuck Closed Y 2 Check Continuity of Idler Solenoid Coil 25 ohms 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 T2. 350 SA PERKINS e Diesel Engine Driven DC Arc Welding Power Source For use with machines having Code Number 10074 or 10074 CV 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 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 OPERATOR S MANUAL ISO 9002 eg e quality Pi SS xd puce n LINCOLN World s Leader in Welding and Cutting Products ELECTRIC Premier Manufacturer of Industrial Motors 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 SAFETY 44 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 chemicals known to the State of California to cause cancer 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 YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH K
3. CHECK ONE CT Please Invoice only if order is over 50 00 C Check or Money Order Enclosed U S Funds only O creditcad 0 0 Ge l USE THIS FORM TO ORDER Books OR FREE INFORMATIVE CATALOGS Lincoln Welding School ED 80 Seminar Information C Procedure Handbook ost Edition 1500 PH T re Howto Read Shop Drawings LB A Educational Video information incentiva Management 500 M M ech A New Approach to Industrial Economics 5 00 NA Lames F Lincoln Arc Welding The American Century of John C Lincoln 55 00 AC i Foundation Book Information C Welding Preheat Calculator 300 wcs l IFES IS ED 89 l TOTAL COST For order value between 50 00 amp 99 99 For order value between 100 00 amp 149 00 paccount no LLLA Ep pen Kl LU 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 O mes Price code Quantity cost BE Y Name Address Telephone Signature as it appears on Charge Card SUB TOTAL Additional Shipping Costs if any FA E E EEE pe m I mL WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO Japanese it is BIR Korean Do not touch electrically live parts or electrode with skin
4. levage cables de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des cables jusqu a ce qu ils se rompent 9 Assurer 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 fortement 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 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie du cops LES MACHINES SOUDER TRANSFORMATEUR ET donc REDRESSEUR Un coup d arc peut tre plus s v re qu un coup de soliel a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du 1 rayonnement de l arc et des projections quand on soude ou quand on regarde l arc 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 personn
5. DO EMPREGADOR SRM OBUOX HD OHRBEE lt K RA ETHBRMLTK EW TLTRHOREMEN ST FEU RA FM E E Rr de AO A RRE ARA MEAR IAE SAAD HALO Aix PAS ERA HEHE Saal veel Gl d illai aul y Llana d AAL all oig Gail call lala ag ls Gras L n STATEMENT OF LIMITED WARRANTY The Lincoln Electric Company Lincoln warrants to the end user purchaser of all new welding and cutting equipment electrode and flux collectively called the Goods that it will be free of defects in workmanship and material This warranty is void if Lincoln or its Authorized Service Facility finds that the equipment has been subjected to improper installation improper care or abnormal operations WARRANTY PERIOD 9 Lincoln will assume both the parts and labor expense of correcting defects during the full warranty period All warranty periods date from the date of purchase to the original end user and are as follows 7 Years Main power rectifiers on all non inverter low frequency 50 and 60 Hz type welders 3 Years All Lincoln welding machines wirefeeders and plasma cutting machines unless listed below 2 Years Power Arc 4000 Power Arc 5000 Ranger 10 Ranger 10 LX Weldanpower 125 Weldanpower 150 1 Year AC 100 Invertec V100 S Invertec V130 S Invertec V200 T Pro Cut 20 All water coolers internal or external models All stick electrode welding wire and flux Arc welding and cutting robots and robotic controllers All
6. Environmental Systems equipment including portable units central units gun and cable assemblies and accessories Does not include consumable items listed under 30 day warranty All welding and cutting accessories including gun and cable assemblies TIG and plasma torches spool guns wire feed modules undercarriages field installed options that are sold separately unattached options welding supplies standard accessory sets replacement parts and Magnum products Does not include expendable parts listed under 30 day warranty 30 Days All consumable items that may be used with the environmental systems described above This includes hoses filters belts and hose adapters Expendable Parts Lincoln is not responsible for the replacement of any expendable part that is required due to normal wear El s ae LIMITED WARRANTY CONDITIONS OF WARRANTY TO OBTAIN WARRANTY COVERAGE The purchaser must contact Lincoln or Lincoln s Authorized Service Facility about any defect claimed under Lincoln s warranty Determination of warranty on welding and cutting equipment will be made by Lincoln or Lincoln s Authorized Service Facility WARRANTY REPAIR If Lincoln or Lincoln s Authorized Service Facility confirms the existence of a defect covered by this warranty the defect will be corrected by repair or replacement at Lincoln s option At Lincoln s request the purchaser must return to Lincoln or its Autho
7. addition of the optional Wire Feed Module for K1314 4 the 350 SA 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 K1314 5 350 SA The output rating of the 350 SA is 350 amperes at 34 arc volts at 25 duty cycle Duty cycle is based on a ten minute period thus the welder can be loaded at rated output for 2 5 minutes out of every ten minute period 60 The output rating at is 250 amps at 40V duty cycle DESIGN SUMMARY Control Panel Both the engine and the welder controls are located on one recessed panel at the exciter 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 button 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 350 SA is equipped with an electric 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
8. battery clamp until snug The 350 SA 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 12 ENGINE OPERATION 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 e 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 3 Use in open well ventilated areas or 5 CA vent exhaust outside 4 MOVING PARTS can injure Do not operate with doors open or guards off A Stop engine before servicing 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 butto
9. idle speed The Idler Control Switch on the panel locks the idler in full speed position when desired Auxiliary Power 3 0 kVA of nominal 115 230V 60 Hz AC Optional Features for Power Plug Kits See 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 K1314 4 5 only Field Installed Provides a receptacle switch and remote control box with 100 ft cord for fine current and OCV adjustment at the welding site Cranking System A 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 OPTIONAL FEATURES Accessory Set K703 Includes electrode and work cables headshield work clamp and electrode holder Ether Start Kit K793 for Perkins Engine When frequent starting is expected below 12 C 10 F remove the thermostart system and install the optional ether start kit to provide maximum cold weather starting assista
10. live parts or electrode with skin or wet clothing Insulate yourself from work and ground FUMES amp GASES can be dangerous 3 Keep your head out of the fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or EIS explosion M gt Keep flammable material away ARC RAYS can burn e Wear eye ear and body protection K NY Duty Cycle The NEMA output rating of the 350 SA 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 44 CAUTION DO NOT TURN THE CURRENT RANGE SELECTOR WHILE WELDING because the current may arc between the contacts and damage the switch The Current Range Selector provides five overlapping 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 preferred for most welding To get this characteristic set the Current Range Selector to the lowest setting that still provides the curre
11. 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 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 instructions in the engine operators 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 conditions 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 necessary 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 troubleshooting instructions Cooling System The 350 SA is equipped with a pressure radiator Keep the radiator cap tight to prevent loss of coolant Clean and flush the cooling system periodically to prevent clogging the passage
12. 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 students 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 A 700 00 lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only IPrices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add l 5 00 For order value up to 49 99 l 10 00 l 15 00 l For North America invoiced orders over 50 00 amp 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
13. 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 seconds starts This time delay cannot be adjusted 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 14 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 configuration 5 15R is provided For the 230V AC power one grounding type duplex receptacle is provided NEMA configuration 6 15R The circuit is protected with circuit breakers The rating of 3 0 kVA permits a maximum continuous 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 permits 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 receptacles 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 pl
14. 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 Ath 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 There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location 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
15. 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 polarity 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 1 200 250 ft 11 PRE OPERATION SERVICE CAUTION READ the engine operating and maintenance instructions supplied with this machine WARNING Fuel can cause fire or explosion Stop engine while fueling Do not smoke when fueling Do not overfill tank Keep sparks and flame away from tank Wipe up spilled fuel and allow fumes to clear before starting engine oil T This unit is supplied from the factory with the engine crankcase filled with a high quality 10W30 oil This oil should be acceptable for most typical ambient temperatures Consult the engine operation manual for specific 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 th
16. E FS MH ae e za SH7IAE elsHAS e S XACE E 2H 43 MASH sai 2 A717 amp 27 amp AMBHI gal ys Jung Ad ale SU ARA bas js oi iail axial e Ah ud Al Aii ge oia sag uc Turn power off before servicing Desconectar el cable de alimentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entretien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servi o XVLFFVYA Y EAKRUD PRE EFFERIA Y FE DFM TKS e HEBES BEER e pHo Meg xp ett AIR Aie Ab pha NM uie ee Jl ale 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 Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas e Vx L S ENQUM CES CRMRBIFELEWTE SEU ERAS AR SHR Ro exo Yel HAE 13 DAS Abiyi ats UN jal lla Ja y e Aale Sual Al ll Aaaa Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO Japanese it ie BIR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURAN A
17. EEP 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 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 FOR ENGINE d 1 h To avoid scalding do not remove the 55 radiator pressure cap when the engine is powered equipment NU ho 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 hy h 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND _ MAGNETIC FIELDS 1 c Do not add the fuel near an open flame may be dangerous welding arc or when the engine is running Stop the engine and allow it to cool before 2 a Electric current flowing through any conductor causes refueling to prevent spilled fuel from localized Electric and Magnetic Fields EMF Welding vaporizing on contact with hot engine parts current creates EMF fields around welding cables and
18. ERATION SERVICE coins ae 12 omm 12 a M 12 Cooling System iii 12 Battery e re UL TEE 12 ENGINE OPERATION ccoo ad Rara iaa 13 Starting the Perkins D3 152 Engine oooococcccccccnncononcnnncnncnnncnnnnnnnnnnnnnnnnnnnnnnnnannnnnnnnnnnn 13 Stopping the Perkins D3 152 EngiM8 ccoo 13 WELDER OP RATION Aa 14 15 DUTY ONE E 14 Controlof Welding Current uni n ias i n ia 14 idler Op rations seance dd i eda diia bi 14 Auxiliary POW Gl wiii aii ai 15 Quads ecce 15 17 General Instructions for Diesel Engine Welders 15 Serb HEIL TUI 16 B arningS H 16 Commutator and Br sFies iiec i 16 Idler Maintenance nennen nemen nennen senes nennen nnn 17 Nairneplate erroe A vus va edu eee redd eee 17 TROUBLESHOOTING iiie dere eite teinte Eden 17 20 Welder Troubleshooting meer nnns 17 19 Flashing the Fields iieri t rr eredi AA nne D e us 19 Electronic Idler Troubleshooting sssssseseeeeeee nnns 20 WIRING DIAGRAM 20 28 iii en nnns nnne ner nnne tenens 21 DIMENSIONI BPRIN dicii secat it n to E Pon eg ev pe ade aaa a eere qu rn hd eu staan teeta pedo Es 22 WELDER PARTS LISTO rire a inertie P237 Series vi GENERAL DESCRIPTION The 350 SA is a heavy duty engine driven DC arc welding power source capable of providing constant current output for stick welding or DC TIG welding With the
19. 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 maintenance man seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact is made across the full face of the brushes After stoning blow out the dust with low pressure air To seat the slip ring brushes position the brushes in place Then slide one end of a piece of fine sandpaper 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 misaligned shaft Have an authorized Field Service Shop check and realign the shaft Idler Maintenance TROUBLESHOOTING A CAUTION Before doing electrical
20. OHSH a MO IVOOT NO HOLINS zeen OL Aaen noraa NEISHOIINZIOd TONLNOD Siwen 404 DOTA TYNOILAO TONLNOD SLOWSH HOLINS S IOVIdSOSH IOWINOD ad vY vc6X CNW 3 M HLIM A9 3 99 D0 SAILISOd HAIIVOEN a Y XooTH AYAT AYTAN HSOISM aaau zao L SNOILDSNNOO ASAHI ONIAVA NAHM ATSNESSY IVLISOWNSHL ONINNOY 3H LON LSOM SNIHOVMW EE aval AAVEH z wzaToH genge DIN OL iozNNOD avat zavan tH mTw IWUSL LNALOO AO BALLVOEN ZTNCON STWNIWESL 104200 gaza sod OL Aaen aum manva Eve roxsnco ces fe wan ux 1 SYOLORNNOD J bes sum 5 x x wo nora no sn WSISHOLLNSIOd TONLNOO Sue HNIHOVH NO er HOIONNNOD OL W d4 M NO Sd DOTA LOBNNOD SD WOIOSNNOD HOYA Id DOTA SAOHSH SNIHOVH NO IVNOILdO HTINAON QH34 JAIM IS 103 93e1n22e aq jou Aeuu y A uo 32U213J914 104 SI LUe1BeIP SIUL LON vs 05 amv OSZ VS AHL NI QHIOZNNOO UV SCV3T NOVIA ANY den FHL AI Linsey T IIM HNIHOVW NO NV TONLNOO SACHEN AHL Ol ZDVVG SNIHOVH SIHI NO QSIOSNNOO LON uv ANY ANO SHNIHDVH I OISSVIO NO QISA HUY Oe XOVIG ANY ATA IHL ANIHOVA NO 80 WOLOZNNOO OL TONINOO SLOWEY NO Edu DOTA xos WBISHOIINS1Od TONLNOD BLONTE NO 6da ONTA SAOWEY ONINNDY LON ENTHOVH HLIM 108NNOO NZHL HOLDENNOD HON SNIHOVM mm mn _ NOILISOd VOOT NI NMOHS TONLNOD SiOWSH I l Ho me wos HOLIMS I I sa Am F LOENNOD 54 zos Les a4 8 1 1 HOLIMS Y SIOWLdEOSN IONLNOD ALONTE uo
21. RUSBRCRBRELTE iD RR HRSRSOREME ex 19 Sal HSE s ESSAI d s die ule Al y lan cl ysl n e A dang 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 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 HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de respiracion Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspirateur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRE EI EULT F n 9 BAPHECTIHIEBLTIA D KEE ER e zc EUR E f
22. Thermostart Glow Plug 1800 RPM 6 5 qts 6 2 ltrs and Engine Protection Low Idle Water 1350 RPM 10 qts 9 5 ltrs PRE OPERATION INSTALLATION Safety Precautions A 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 e 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 3 a vent exhaust outside MOVING PARTS can injure VE Do not operate with doors open or guards off RN Stop engine before servicing Keep away from moving parts 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 CAUTION Use of an incorrect arrester may lead to engine damage or performance loss C
23. a ona IWNOILdO TOHLNOD HLONHA I v 6X asve OL HHWHOSSNVHI INSNH O wOIVNHEITV x SONIGNIM amoa AHVITIXOV HOLVNNHITV HOLIMS MOLOSTSS LVLSOSHN EEGEN LTOA Ott NONI OL LSHHVHN ONIY dITS SONIY dITS YHOLOY HOLVNAALTV Ei M da sc 1 6 OT II ety IIVH DV SQNOOOVN HULNEN ENVIA OL QHOINOS TIVNIOHN NVHN NOVA GHMAIA SV NMOHS SINSNOGNOD TANYA TOWINOD anna NOILORDNI nana E D 278 HOLIMS ansssua 110 DEEN LIOA SIT arona1os P HOLIMS ATTI KINO SLINO gang NO sesadv sawat NMOYE N NHHND 5 xovigs s8 doo 407100 aval LESTE wad STOSWAS IVOINLDETE WVHOVIG ONTAIM WS OSE HOLOW DNILUVLS UJ L apoyo ZUNLVSZAMAL S ON ON Kg Laws oa an vr s4S gend LI AALAN NOILINDI noH SNIDNH HOLIMS ANTAN NOILOSl1ONd ANIONA 47 i WHLINDI LuVISONHSHI DIMENSION PRINT 114 5 109 6 83 4 45 07 43 13 32 82 WITH OIL AND WATER IN ENGINE BUT NO FUEL 1 5 59 X 2 8 1 10 SLOTS 1 8 69 DIA HOLES MEASUREMENTS ARE IN CM IN M8869 24 7 27 90C Now Available 12th Edition The Procedure Handbook of Arc Welding With 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
24. amage to the engine alternator and the printed circuit board can result from incorrect connection 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 replacement item number DE 2m e 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 23 Use in open well ventilated areas or E GA vent exhaust outside 4 MOVING PARTS can injure Do not operate with doors open or guards off NY Stop engine before servicing N Keep away from moving parts See additional warning information at front of this operator s manual TROUBLE A Machine fails to hold the heat consistently B Welder starts but fails to generate current C Welding arc is loud and spatters excessively TROUBLESHOOTING CAUSE WHAT TO DO 1 1 Rough or dirty commutator Brushes may be worn down to limit Field circuit may have variable resistance connection or intermittent open circuit due to loose connection or broken wire Electrode lead or work lead connection may be poor Wrong grade of brushes may have been installed on generator Field rheostat may be making poor contact and overheating Generator or excite
25. and igniting Do not spill fuel when filling welding machines tank If fuel is spilled wipe it up and do not start engine until fumes have been Es EMF fields may interfere with some pacemakers and eliminated welders having a pacemaker should consult their physician before welding Exposure to EMF fields in welding may have other health effects which are now not known K All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 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 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 In some cases it may be necessary to remove safety 2 d 3 Do not place your body between the electrode and guards to perform required maintenance Remove work cables If the electrode cable is on your right guards only when necessary and replace them when the side the work cable should also be on your right side maintenance requiring their removal is complete Always use the greatest care when working near moving d 4 Connect the work cable to the workpiece as close as parts possible to the area being welded Do not put your hands near the engine fan Do not atte
26. and overheating the engine When antifreeze is needed always use the permanent type ORDERING COOLING SYSTEM INFORMATION CAPACITY K1314 ALL 10 Quarts Bearings This welder is equipped with a double shielded ball bearing having sufficient grease to last indefinitely under normal service Where the welder is used constantly or in excessively dirty locations it may be necessary 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 clean equipment More bearing failures are caused by dirt introduced during greasing than from insufficient grease Commutator amp Brushes A 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 rotating 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 Periodically inspect the commutator slip rings and brushes by removing the covers DO NOT remove or replace these covers while the machine is running Commutators and slip rings require little attention
27. athing 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 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 LINCOLN B SAFETY 3 7 WELDING 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 s
28. e grade of fuel recommended in the Engine Operators 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 solution as needed See engine manual or antifreeze container from alternate antifreeze recommendation Battery Charging A WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away BATTERY ACID can burn eyes and skin Wear gloves and eye protection and be careful when boosting charging or dE 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 b Connecting a battery charger remove the battery from the welder by disconnecting the negative cable first then the positive cable and battery clamp When reinstalling connect the negative cable last c Using a booster connect the positive lead to the battery first then connect the negative lead to the ground lead on the base To prevent ELECTRICAL DAMAGE when a Installing a new battery b Using a booster Use correct polarity Negative Ground To prevent BATTERY DISCHARGE if you have an ignition switch turn it off when engine is not running To prevent BATTERY BUCKLING tighten nuts on
29. ed 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 open 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 ARC RAYS can burn 4 a Use a shield with the proper filter and cover Le 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 bre
30. el travaillant proximit au soudage l aide d crans appropri s et non inflammables 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 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les LINCOLN P Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif 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 V V for selecting a QUALITY product by Lincoln Electric We want you hank You to take pride in operating this Lincoln Electric Company product 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
31. es 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 Premier Manufacturer of Industrial Motors s Aaa El June 98
32. g 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 K1314 4 and factory installed on the K1314 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 manual SPECIFICATIONS Machine Product Ordering 1 Description Rated DC Output 2 Current Range Auxiliary Dimensions amp Weight Name Information Amps Volts Duty Cycle psoe recta y Power HxWxL 350 Amp DC 350 SA K1314 4 i j 40 375 Amps kVA i Arc Welder Lincoln Rating 5 Amp 3 43 1 x 28 x 67 in Perkins WFM 350A 34V 1096 x 711 x 1702 mm Field 220 Max 115 230V Installed Stick DC TIG 23 Duty Cycle 160 240 S 120 190 Weldin K1314 5 9 NEMA Rating 80 130 742 5 kg WFM 250A 30V Mii s 90 Factory Pure DC Power 60 Duty Cycle Installed Generator Beete 1 WFM Wire Feed Module 2 Based on a 10 Minute Period Engine Product Description Horsepower Operating Displacement Capacities Name Speeds Perkins D3 152 3 Cylinder Full Load Full Load Fuel 4 Cycle 38 2 HP 1725 RPM 15 gals 57 ltrs Water C ooled 1725 RPM Diesel Engine with High Idle Oil
33. lists a number of alternate means of grounding electrical equipment Lift Bail A lift bail is provided for lifting with a hoist A WARNING BR FALLING EQUIPMENT can cause injury Do not lift this machine using lift bail if it is equipped with a heavy accessory such as a trailer or gas cylinder 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 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 10 3 Proper placement of the equipment on the undercarriage 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 speed roughness of surface on which the trailer will be operated environmental conditions amp likely maintenance 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 Polarity Control amp
34. mpt d 5 Do not work next to welding power source to override the governor or idler by pushing on the throttle control rods while the engine is running LINCOLN B SAFETY 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 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 weld
35. n d Press the START button Release button when engine starts e If the engine fails to start in 60 seconds wait 30 seconds before repeating the above procedure f Allow the engine to run at high idle speed for several minutes to warm up Cold engines tend to run at a speed too slow to supply the voltage required for proper idler operation Cold Weather Starting When overnight temperatures are between 12 C 10 F 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 18 C 0 F If the engine must be frequently started below 12 C 10 F 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 Engine 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 system Check the crankcase oil and radiator water level WELDER OPERATION A WARNING e ELECTRIC SHOCK can kill Do not touch electrically
36. n 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 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 a deux machines a souder parce que la tension entre les deux pinces peut tre le total de la tension a vide des deux machines Si on utilise la machine a 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 prot ger pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince 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
37. nce 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 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 damage to pipes burning up the welder or other hazards 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 350 SA Perkins Power Plug Kit K802C A power plug kit for the auxiliary power receptacles is available Provides a plug for each receptacle Trailer K769 Two wheeled trailer for in plant and yard towing only For highway use consult applicable federal state and local laws regarding possible requirements for brakes lights fenders etc 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 regardin
38. nt 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 When a forceful digging arc is required usually for vertical and overhead welding use a higher Current Range Selector setting and lower open circuit voltage 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 44 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 operating speeds are as follows ORDERING FULL HIGH LOW INFO LOAD IDLE IDLE K1314 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 gt position
39. ontact 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 unrestricted flow of clean cool air Also locate the welder so that the engine exhaust fumes are properly vented to an outside area 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 National Electrical Code
40. or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa mojada Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v tements mouill s entrer en contact avec des pi ces sous tension e Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e Isolieren Sie sich von den Elektroden und dem Erdboden e Nao toque partes el tricas e electrodos com a pele ou roupa molhada Isole se da peca e terra o REPOR iAH IPANERTHNEULE O LIMET XH CS pr NTWSHIELTFSU ORAR IDEAR 94 MIER HIER e Sal SUELES Xe su uc qe sup Baa nisle e Su AXE HFA ola Jal Lei Gre gi el ai gual ye deal Zei ay SN gh uil gl suit Ald play dani DA dus ule die pg Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guardados e nadioe6oolcositEx BEXILTEENEtA e i 9 Vi S BET PBA else S88 Ac AIX ng Am Sn Jan AL al gt a e Wear eye ear and body protection Prot jase los ojos los oidos y el cuerpo 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 e BH H
41. parks 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 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 po
42. r 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 1 See FLASHING THE FIELDS on following page 18 Commutator should be turned or cleaned Replace brushes Check field current with ammeter to discover varying current This applies to both the main generator 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 rheostat field leads and field coils Check rectifier bridge Flash fields 1 Check circuit with ringer or voltmeter Check setting and current output With ammeter Check polarity Try reversing polarity or try an electrode of the opposite polarity 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 output compared to dial indication on the dial indication Operating speed too low or high Adjust speed screw on governor for 1800 RPM operating speed E Arc continuously pops out
43. rized Service Facility any Goods claimed defective under Lincoln s warranty FREIGHT COSTS The purchaser is responsible for shipment to and from the Lincoln Authorized Service Facility WARRANTY LIMITATIONS Lincoln will not accept responsibility or liability for repairs made outside of a Lincoln Authorized Service Facility Lincoln s liability under this warranty shall not exceed the cost of correcting the defect of the Lincoln product Lincoln will not be liable for incidental or consequential damages such as loss of business etc caused by the defect or the time involved to correct the defect This written warranty is the only express warranty provided by Lincoln with respect to its products Warranties implied by law such as the warranty of merchantability are limited to the duration of this limited warranty for the equipment involved This warranty gives the purchaser specific legal rights The purchaser may also have other rights which vary from state to state Equipment manufactured for the Lincoln Electric Company is subject to the warranty period of the original manufacturer All engines and engine accessories are warranted by the engine or engine accessory manufacturer and are not covered by this warranty 1 SAE400 WELD N AIR compressor is warranted by the compressor manufacturer and not covered by this warranty aaa LINCOLN E World s Leader in Welding and Cutting Products ELECTRIC Sal
44. ry 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 Jequunu epoo quauudinbe au SAID 3u8uJe2e dai e 104 3ueuniedeg aus ou 01 SUM e qgibal si Weep ay 4 sjeued aunso dus y Jo euo uo aulyoeu ayy opisul pa3sed si opoo jejnonued e Joy Weep 2u12ade SUL Jenueuu siy Aq palano gt SauIy3euu osten TL6 tt 0T WS 0st ANY OSz VS JHL NI G123NNOO sav zeen xovg INV gen HHL 4I mess TIIM SNIHOVH NO GNY IOWLNOD SACHEN HHL Ol HOVHVA ANTHOVA SIMI NO ABIDENNOD LON SHY ANY ATNO SENTHOVA I DISSWIO NO geen SAY SAYT YOWTE ANY den SHE GETIVISNI STATOR GEES HAIM V NO gement SOTA Tld SHE 1DOHLIM geen SI LI 4I HOLIMS TOWLNOD SLOWEY ZHL OL 80DDO NWO SOWAYO NOLLOWO ENIHOWA SHL NO ep MOIOSNNOD OL LIX IONINOO BLOWS WOUd ld DOTA LOBNNOD SC YOLDENNOD HOJA SNIHOVM SHL NO 0Tdu DATA IOSNNOOSIG 440 SNIHOVM ZHL HLIM GSTTVLSNI SI EINIOM QS34 FAIM ON AT AELOENNODNA LI ONIAVST ASNVSN TIdu ONTd MEN GHI NELSVA ANIHOVA HHL NO SI ENO 4I OTda 90TA GSIOGNNOOND AHL 40 3SO4SIG 4dO SNIHOVM ZHL HLIM ONTIViSNI SI BINGOW Gass BYIM V AI SNIHOVH NO BD YOLOBNNOD OL LIX TONLNOD BLOMEU NO Bd DATE LOSNNOO gent u WOIOSNNOO MONA SNIHOVH NO 6d OOTA SAOMSH AIO ZNIHOVH HLIM x XOS WSISHOILNSLOd AMOHS ONLNOO Si
45. s in use or connected for use 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 FOR ELECTRICALLY 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 i SAFETY i PRECAUTIONS DE SURETE zones o Pon pique le laitier Pour votre propre protection lire et observer toutes les instructions 6 Eloigner les mat riaux inflammables ou les recouvrir afin de 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 a 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 bie
46. sition 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 circuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c LINCOLN B CYLINDER may explode or ION g 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 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 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 i
47. 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 A 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 1 10 mirate tddi i dde 7 pissiten EB npisg 7 OPTIONAL FEATURES ees geet id Ede PE La FARE LEO 8 SPECIFICATION S O 9 PRE OPERATION INSTALLATION 1 22 2 6 teed a 10 11 Safety Precautions sise 10 Exhaust Spark Arrestan es eta ree a 10 Location Ventilation ss 10 Machine Grounding reco retorno Matin ita Pee ana 10 Cift BAR RE a a te AE nee Ci 10 e HE 10 11 Polarity Control and Cable Gizes ss 11 PRE OP
48. ug 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 MAINTENANCE A WARNING Have qualified personnel do the maintenance work Turn the engine off before working inside the machine In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working 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 K o 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 3 Use in open well ventilated areas or a GA vent exhaust outside 4 MOVING PARTS can injure Do not operate with doors open or guards off Se Stop engine before servicing Keep away from moving parts D 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
49. work on the idler printed circuit board disconnect the battery 1 The solenoid plunger must work freely because binding can cause engine surging If surging occurs be sure the plunger is properly lined up with the throttle lever Dust the plunger about once a year with graphite powder 2 When any service is done reassemble the rubber bellows on the solenoid plunger with the vent hole on the lower side 3 Proper operation of the idler requires good grounding of the printed circuit board through its A WARNING Have qualified personnel do the troubleshooting work Turn the engine off before working inside the machine In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working 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 mounting reed switch and battery a ELECTRIC SHOCK can kill 4 f desired the welder can be used without automatic 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 D
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