Cable Control Kit Instructions
New SA 300 D Instructions

All you need to do is plug in the male TL plug into the female TL plug on the welding machine and plug in the 110 plug into the 110 plug on your machine. Use the Lincoln switch on machine for your Local-Off-Remote.


Lincoln SA 250 AC, Gas, Diesel & Classic II & III

The Control Kit Box allows you to run your grinder under fuse protection, plus the heat will be at your finger tips. The box will be dead when the switch is directed for the welding machine Rheostat. You can still use your tools at any time. Both Rheostats will be dead when the switch is in the center position and you can't weld.

Step 1. Drill a hole where desired (1/2 in.), but allowing for length of wire on switch to reach Rheostat on welding machine. ON YOUR CLASSICS ONLY you have a factory cross shaped hole in the center of the back panel. Punch it out and use the extra switch plate (in invoice) on the back and one on the instruction sheet on the front to hold the switch on. No hole to drill.
Step 2. Remove wire from center terminal that aligns with shaft in center of Rheostat on machine. Replace with short wire from switch. The wire taken from center of Rheostat goes on the center lug of the switch. On your classic II or III you may take both wires off and put on middle of switch.

NOTE: DO NOT REMOVE ANY OTHER WIRE FROM RHEOSTAT.
Step 3. Loosen nut of OFF-SET lug of Rheostat, then place on light red wire with spaded lug. Re-tighten nut.
Step 4. Plug goes into 110 receptacle on back or front of your machine.
ATTENTION: Our units are ONLY designed to go hard wire to the factory Rheostat on your machine, not to be wired into plug that is designed just for Lincoln Accessories such as portable wire boxes and the flux core wire welders.
CAUTION: For your information the 110 volt line on your unit is not safety grounded. Use DOUBLE insulated hand tools only.
NOTE: Please do not remove any wires from switch when you receive your kit. The green wire goes on one side of switch and short black wire on the other side of switch.


New SA 200 G or D Instructions

All you need to do is plug in the Male Twist Lock Plug into your welding machine. Put your own cord, no smaller than a 16/3 wire, between my yellow female plug on cheater plug and the male plug from the box pigtail.

If your Cable Control Kit box is getting hotter than usual, first check your oopen circuit voltage, it should be running 93 volts and it is more probably the RPMs are to high, plus, the new 200 Ds have approximate 400 more windings than the regular 200 Machines. For more information call Tom Fowler at 985-384-6914.

ATTENTION! If you want to put the twist lock plug on your existing extension cord please wire it to your cord the same as we have it wired to the short adapter. You will also need to take the regular female three prong plug on our adapter and wire it the same as we have it wired to the other end of your extension cord. This will save you from burning your rheostat up.


Instructions For Lincolns SA 200 Amp & SA 25 Amp Auxilary 110 DC ONLY

CAUTION
Our new concept of the Control Kits allows you to buy the extension cord length and size. (I recommend nothing smaller than guage 16/3 wire.) The caution warnings are to impress upon you that you need to be sure the cord you put in between my plugs on my unit has the plugs wired to code. My plugs are not wired to code but wire to my own design. When you have to replace any of the plugs on the unit I sell you, they should be wired the same as when you take them off.
Step 1. Drill hole (15.32) where desired but allowing for length of wire on switch to reach Rheostat on welding machine. On your Classic ONLY you have a factory cross shaped hole in the center of the back panel. Punch it out and use the extra switch label (in invoice) in the back and the one on the instruction sheet on the front to hold the switch on. NO hole to drill.
Step 2. Remove wire from center terminal that aligns with shaft in center of Rheostat on machine. Replace with short wire from switch. The wire taken from center of Rheostat goes on the vacant center lug of switch. ON your newer Classic 1 you may use both wires from center of Rheostat and put on the center lug of switch.
NOTE: DO NOT REMOVE ANY OTHER WIRES FROM RHEOSTAT.
Step 3. Loosen nut of OFF-SET lug of Rheostat, then place on black wire with spaded lug, Re-tighten nut.
Step 4. On newer machines with PC boards find short wire going from board to receptacle and crimp green wire with the blue clip into it making sure the green wire is in blue clip far enough for the spade to cut into wire.

On older machines, one wire on the receptacle goes to Rheostat. Find the opposite wire on recepticle and crimp green wire with blue clip into it, making sure the green wire is in blue clip far enough for spade to cut into wire.

On your Classic 1 ONLY: Clip your green wire onto the black in between the fuse and the factory receptacle.

Step 5. Use the plastic wire tie to tie the wire to the choke cable, etc.


New SA 200 Kit Instructions

Take off one side at a time on your old recept. on your welding machine.

1. First locate wire on old recept that goes from recept to offset post on Rheostat. Take both wires on this side of old recept and put on the Brass Screw of new recept. The offset post will be a 2:00 o'clock or 8:00 o'clock on machine, depending on how its mounted on your machine.

2. The other wire or wires on other side of old recept goes to Silver Screw on new recept.

3. To Install Switch: Take wire off of center post of Rheostat, (It will be at 3:00 o'clock or 9:00 o'clock on your machine Rheostat) and put on center post of switch. Then take jumper wire from switch and put on center post of machine Rheostat.

4. When Mounting Switch: Rotate switch with jumper wire on top. This will align it to switch label.

Do not flip switch while machine is running.

This new adapter kit allows you to run your tools and control kit from same recept at all times.


From SA 250 to 300 D TL Plug Adapter

1. To install TL Plug & Switch: Take wire or wires off of center post of rheostat. Put these wires on center post of switch. Take jumper wire from switch and put on center post of rheostat.

2. Take red wire from TL Plug and add it to the offset post of rheostat.

3. When mounting switch, take extra switch label and use it for a spacer on switch. Rotate switch with jumper wire on top. This will align it to switch label.

Do not flip switch while machine is running.

This kit allows vou to convert your SA 250 machine to a 300 D hook-up and allows a Lincoln remote to work off of it also.

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